description
stringlengths 4.57k
100k
| abstract
stringlengths 89
2.31k
| description_length
int64 4.57k
100k
|
|---|---|---|
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. Ser. No. 08/814,366, filed Mar. 11, 1997 U.S. Pat. No. 6,124,495.
FIELD OF THE INVENTION
This invention relates to compositions for and methods of treating, preventing or ameliorating cancer and other proliferative diseases as well as methods of inducing wound healing, treating cutaneous ulcers, treating gastrointestinal disorders, treating blood disorders such as anemias, immunomodulation, enhancing recombinant gene expression, treating insulin-dependent patients, treating cystic fibrosis patients, inhibiting telomerase activity, treating virus-associated tumors, especially EBV-associated tumors, modulating gene expression and particularly augmenting expression of tumor suppressor genes, inducing tolerance to antigens, treating, preventing or ameliorating protozoan infection or inhibiting histone deacetylase in cells. The compositions of the invention are to and the methods of the invention use unsaturated oxyalkylene esters.
BACKGROUND OF THE INVENTION
Butyric acid (BA) is a natural product. It is supplied to mammals from two main sources: 1) the diet, mainly from dairy fat, and 2) from the bacterial fermentation of unabsorbed carbohydrates in the colon, where it reaches mM concentrations (Cummings, Gut 22:763-779, 1982; Leder et al., Cell 5:319-322, 1975).
BA has been known for nearly the last three decades to be a potent differentiating and antiproliferative agent in a wide spectra of neoplastic cells in vitro (Prasad, Life Sci. 27:1351-1358, 1980). In cancer cells, BA has been reported to induce cellular and biochemical changes, e.g., in cell morphology, enzyme activity, receptor expression and cell-surface antigens (Nordenberg et al., Exp. Cell Res . 162:77-85, 1986; Nordenberg et al., Br. J. Cancer 56:493-497, 1987; and Fishman et al., J. Biol. Chem . 254:4342-4344, 1979).
Although BA or its sodium salt (sodium butyrate, SB) has been the subject of numerous studies, its mode of action is unclear. The most specific effect of butyric acid is inhibition of nuclear deacetylase(s), resulting in hyperacetylation of histones H3 and H4 (Riggs, et al., Nature 263:462-464, 1977). Increased histone acetylation, following treatment with BA has been correlated with changes in transcriptional activity and the differentiated state of cells (Thorne et al., Eur. J. Biochem . 193:701-713, 1990). BA also exerts other nuclear actions, including modifications in the extent of phosphorylation (Boffa et al., J. Biol. Chem . 256:9612-9621, 1981) and methylation (Haan et al., Cancer Res. 46:713-716, 1986). Other cellular organelles, e.g., cytoskeleton and membrane composition and function, have been shown to be affected by BA (Bourgeade et al., J. Interferon Res .1:323-332, 1981). Modulations in the expression of oncogenes and suppressor genes by BA were demonstrated in several cell types. Toscani et al., reported alterations in c-myc, p53 thymidine kinase, c-fos and AP2 in 3T3 fibroblasts ( Oncogene Res .3:223-238, 1988). A decrease in the expression of c-myc and H-ras oncogenes in B16 melanoma and in c-myc in HL-60 promyelocytic leukemia was also reported (Prasad et al., Biochem. Cell Biol . 68:1250-1255, 1992; and Rabizadeh et al., FEBS Lett. 328:225-229, 1993).
BA has been reported to induce apoptosis, i.e., programmed cell death. SB has been shown to produce apoptosis in vitro in human colon carcinoma, leukemia and retinoblastoma cell lines (Bhatia et al., Cell Growth Diff . 6:937-944, 1995; Conway et al., Oncol. Res . 7:289-297, 1993; Hague et al.; Int. J. Cancer 60:400-406, 1995). Apoptosis is the physiological mechanism for the elimination of cells in a controlled and timely manner. Organisms maintain a delicate balance between cell proliferation and cell death, which when disrupted can tip the balance between cancer, in the case of over accumulation of cells, and degenerative diseases, in the case of premature cell losses. Hence, inhibition of apoptosis can contribute to tumor growth and promote progression of neoplastic conditions.
The promising in vitro antitumor effects of BA and BA salts led to the initiation of clinical trials for the treatment of cancer patients with observed minimal or transient efficacy [Novogrodsky et al., Cancer 51:9-14, 1983; Rephaeli et al., Intl. J. Oncol . 4:1387-1391, 1994; Miller et al., Eur. J. Cancer Clin. Oncol . 23:1283-1287, 1987].
Clinical trials have been conducted for the treatment of β-globin disorders (e.g., β-thalassemia and sickle-cell anemia) using BA salts. The BA salts elevated expression of fetal hemoglobin (HbF), normally repressed in adults, and favorably modified the disease symptoms in these patients (Stamatoyannopouos et al., Ann. Rev. Med . 43:497-521, 1992). In this regard, arginine butyrate (AB) has been used in clinical trials with moderate efficacy (Perrine et al., N. Eng. J. Med . 328:81-86, 1993; Sher et al., N. Ens. J. Med . 332:1606-1610, 1995). The reported side effects of AB included hypokalemia, headache, nausea and vomiting in β-thalassemia and sickle-cell anemia patients.
Butyric acid derivatives with antitumor activity and immunomodulatory properties have been reported in U.S. Pat. No. 5,200,553 and by Nudelman et al., 1992 , J. Med. Chem . 35:687-694. The most active buryric acid prodrug reported in these references was pivaloyloxymethyl butyrate (AN-9). Similar compounds were reported for treating hemoglobinopathies (U.S. Pat. No. 5,569,675).
BA and/or its analogues have also been reported to increase the expression of transfected DNA (Carstea et al., 1993 , Biophys. Biochem. Res. Comm . 192:649; Cheng et al., 1995 , Am. J. Physical 268:L615-L624) and to induce tumor-restricted gene expression by adenovirus vectors (Tang et al., 1994 , Cancer Gene Therapy 1:15-20). Tributyrin has been reported to enhance the expression of a reporter gene in primary and immortalized cell lines (Smith et al., 1995 , Biotechniques 18:852-835).
However, BA and its salts are normally metabolized rapidly and have very short half-lives in vivo, thus the achievement and maintenance of effective plasma concentrations are problems associated with BA and BA salts, particularly for in vivo uses. BA and BA salts have required large doses to achieve even minimal therapeutic effects. Because of the high dosage, fluid overload and mild alkalosis may occur. Patients receiving BA eminate an unpleasant odor that is socially unacceptable.
While BA salts have been shown to increase HbF expression, and appear to hold therapeutic promise with low toxicity in cancer patients, they nevertheless have shown low potency in in vitro assays and clinical trials.
There remains a need to identify compounds as effective or more effective than BA or BA salts as differentiating or anti-proliferating agents for the treatment of cancers. Such compounds need to have higher potency than BA without the problems associated with BA (such as bad odor). This need can be addressed by therapeutic compounds that either deliver BA to cells in a longer acting form or which have similar activity as BA but a longer duration of effectiveness in vivo.
The compounds of this invention address these needs and are more potent than BA or BA salts for treating of cancers and other proliferative diseases, for treating gastrointestinal disorders, for wound healing, for treating blood disorders such as thalassemia, sickle cell anemia and other anemias, for modulating an immune response, for enhancing recombinant gene expression, for treating insulin-dependent patients, for treating cystic fibrosis patients, for inhibiting telomerase activity, for treating virus-associated tumors, especially EBV-associated tumors, for modulating gene expression and particularly for augmenting expression of a tumor suppressor gene, for inducing tolerance to an antigen, for treating, preventing or ameliorating protozoan infection and for inhibiting histone deacetylase in cells.
Certain compounds used in the methods of this invention have been reported. For example, the use of substituted dicinnamic acid oxymethylene esters as sensitizers has been described in Japanese Patent No. 01128872 for use in thermal recording materials. The uses of substituted methoxy and hydroxy dicinnamic acid oxymethylene esters as anti-hepatotoxic agent have been described (Kiso et al, 1983 , Planta Med . p .185). Finally, German Patent No. 2,625,688 reports the use of butyl and cinnamic acid substituted oxymethylene esters as a anticholesteremic agent.
SUMMARY OF THE INVENTION
Accordingly, one embodiment of the present invention is directed to a method of treating preventing or ameliorating cancer and other proliferative disorders using compounds represented by Formula (I):
wherein
R is C 2 -C 10 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, aryl or heteroaryl, any of which can be optionally substituted with halo, trifluoromethyl, hydroxy, alkoxy, cyano, nitro or carbonyl, wherein the heteroatom of said heteroaryl is oxygen or sulfur;
R 1 and R 2 are independently H, C 1 -C 10 alkyl, C 2 -C 10 alkenyl, or C 2 -C 10 alkynyl, any of which can be optionally substituted with halo, alkoxy, amino, trifluoromethyl, aryl or heteroaryl;
A is
R 3 is
R 4 , R 5 , R 6 and R 7 are independently H, alkyl or alkenyl;
B is aryl or heteroaryl, wherein the heteroaton of said heteroaryl is oxygen or sulfur;
m and n are independently 0 to 5;
the sum of m and n is 1 to 5;
p, q and r are independently 0 to 2; or
a pharmaceutically-acceptable salt thereof.
The above compounds can be used in all the methods of the invention. In a preferred embodiment, the compounds used in this and the other methods of the invention are those of Formula (I), wherein m is 1 to 5; n is 0 to 5; and p is 0. In another preferred embodiment, R 2 is H. Still more preferred are the compounds of Formula (I), wherein
R is n-propyl, benzyl, 3-(phenyl)propyl, 2-chloroethyl, 2-propenyl;
R 1 is H or alkyl;
R 3 is
R 6 and R 7 are independently H or alkyl; and n, q and r are 0.
In a most preferred embodiment, the compounds are cinnamoyloxymethyl butyrate; cinnamoyloxymethyl phenylacetate; cinnamoyloxymethyl 4-phenylbutyrate; 1- (cinnamoyl)oxyethyl phenylacetate; 1-(cinnamoyl)oxyethyl 4-phenylbutyrate; 3,4-dimethoxycinnamoyloxymethyl butyrate; or 1-(3,4-dimethoxycinnamoyl)oxyethyl butyrate.
The compounds of Formula (I) are particularly useful for methods of treating, preventing or ameliorating the effects of cancer and other proliferative disorders by acting as anti-proliferative or differentiating agents in subjects afflicted with such anomalies. Such disorders include, but are not limited, to leukemias, such as acute promyelocytic leukemia, acute myeloid leukemia, and acute myelomonocytic leukemia; other myelodysplastic syndromes, multiple myeloma such as but not limited to breast carcinomas, cervical cancers, melanomas, colon cancers, nasopharyngeal carcinoma, non-Hodgkins lymphoma (NHL), Kaposi's sarcoma, ovarian cancers, pancreatic cancers, hepatocarcinomas, prostate cancers, squamous carcinomas, other dermatologic malignancies, teratocarcinomas, T-cell lymphomas, lung tumors, gliomas, neuroblastomas, peripheral neuroectodermal tumors, rhabdomyosarcomas, and prostate tumors and other solid tumors. It is also possible that compounds of Formula (I) have anti-proliferative effects on non-cancerous cells as well, and may be of use to treat benign tumors and other proliferative disorders such as psoriasis. Preferred is the method for treating or ameliorating leukemia, squamous cell carcinoma and neuroblastoma.
The invention is further directed to a method of treating blood disorders by administering a therapeutically-effective amount of a compound of Formula (I) to a patient.
The blood disorders treatable in accordance with the invention include, but are not limited to, thalassemias, sickle cell anemias, infectious anemias, aplastic anemias, hypoplastic and hypoproliferative anemias, sideroblastic anemias, myelophthisic anemias, antibody-mediated anemias, anemias due to chronic diseases and enzyme-deficiencies, and anemias due to blood loss, radiation therapy and chemotherapy. In this regard, these methods can include increasing hemoglobin content in blood by adminstering a therapeutically-effective amount of a compound of Formula (I) to a subject.
Another embodiment of the invention is directed to a method of modulating an immune response in. a host by administering an amount of a compound of Formula I is effective to modulate said immune response.
Modulation of the immune response includes enhancing cytokine secretion, inhibiting or delaying apoptosis in polymorphonuclear cells, enhancing polymorphonuclear cell function by augmenting hematopoietic growth factor secretion, inducing expression of cell surface antigens in tumor cells, and enhancing progenitor cell recovery after bone marrow transplantation.
The pharmaceutical agents of the invention for the above method include, but are not limited to, cytokines, interleukins, anti-cancer agents, chemotherapeutic agents, antibodies, conjugated antibodies, immune stimulants, antibiotics, hormone antagonists, and growth stimulants. The compounds of the invention can be administered prior to, after or concurrently with any of the agents.
Yet another embodiment of the invention is directed to a method of ameliorating the effects of a cytotoxic agent which comprises administering a therapeutically-effective amount of a cytotoxic agent with a compound of Formula (I) to a mammalian patient for a time and in an amount to induce growth arrest of rapidly-proliferating epithelial cells of the patient and thereby protect those cells from the cytotoxic effects of the agent. The cytotoxic agent can be a chemotherapeutic agent, an anticancer agent, or radiation therapy. Rapidly proliferating epithelial cells are found in hair follicles, the gastrointestinal tract and the bladder. Such cells include hair follicle cells, or intestinal cryt cells. Rapidly proliferating cells are also found in the bone marrow and include bone marrow stem cells. In accordance with the invention the cytotoxic agent and the compound of Formula (I) can be administered simultanously, or the cytotoxic agent can be administered prior to or after the compound of the invention. Administration (simultaneously or separately) can be done systemically or topically as determined by the indication. In addition, when the cytotoxic agent is radiation therapy, the compounds of the invention can be administered to a cancer patient pre- or post-radiation therapy to treat or ameliorate the effects of cancer.
A still further embodiment of the invention is directed to a method of inducing wound healing, treating cutaneous ulcers or treating a gastrointestinal disorder by administering a therapeutically-effective amount of a compound of Formula (I) to a subject in need of such treatment. The cutaneous ulcers which can be treated in accordance with the methods of the invention include leg and decubitus ulcers, stasis ulcers, diabetic ulcers and atherosclerotic ulcers. With respect to wound healing, the compounds are useful in treating abrasions, incisions, burns, and other wounds. Gastrointestinal disorders treatable by the methods of the invention include colitis, inflammatory bowel disease, Crohn's disease and ulcerative colitis.
A further embodiment of the invention relates to a method of enhancing recombinant gene expression by treating a recombinant host cell containing an expression system for a mammalian gene product of interest with an expression-enhancing amount of a compound of Formula (I), wherein said gene product is encoded by a butyric acid-responsive gene. The host cells can be mammalian cells, insect cells, yeast cells or bacterial cells and the correspondingly known expression systems for each of these host cells. The gene product can be any protein or peptide of interest, expression of which can be regulated or altered by butyric acid or a butyric acid salt. A butyric acid-responsive gene is a gene that has a promoter, enhancer element or other regulon that modulates expression of the gene under its control in response to butyric acid or a salt of butyric acid. For example, gene products contemplated for regulation in accordance with the invention include but are not limited to tumor suppressor genes (such as p53) and the γ-globin chain of fetal hemoglobin.
Yet a further embodiment of the invention is directed to a method of treating, preventing or ameliorating symptoms in insulin-dependent patients by administering an amount of a compound of Formula (I) effective to enhance insulin expression.
Yet another embodiment of the invention relates to a method of treating, preventing or ameliorating symptoms in cystic fibrosis patients by administering an amount of a compound of Formula (I) effective to enhance chloride channel expression.
Still another method of the invention is directed to a method of inhibiting telomerase activity in cancer cells by administering a telomerase-inhibiting amount of a compound of Formula (I) to the cells, wherein the amount is effective to decrease the telomerase activity of the cells and thereby inhibit the malignant progression of the cells. This method can be applied to in vivo or in vitro cells.
Another embodiment of this invention is directed to a method of treating, preventing or ameliorating virus-associated tumors by pre-, post or co-administering a therapeutically-effective amount of a compound of Formula (I) with a therapeutically-effective amount of an antiviral agent. Antiviral agents contemplated for use in the invention include ganciclovir, acyclovir and famciclovir, and preferably ganciclovir. The virus-associated tumors which can be treated, prevented or ameliorated in accordance with the invention include, but are not limited to, EBV-associated malignancy, Kaposi's sarcoma, AIDS-related lymphoma, hepatitis B-associated malignancy or hepatitis C associated malignancy. EBV-associated malignancies include nasopharyngeal carcinoma and non-Hodgkins' lymphoma and are preferred embodiments of the invention.
Further still, the invention provides a method of modulating gene expression by treating a host or host cells with an amount of a compound of Formula I effective to enhance, augment or repress the expression of a gene of interest, preferably a buytric acid responsive gene. When expression of the gene of interest is to be enhanced or augmented, the gene can encode a gene product which is or acts as a repressor of another gene, a tumor supressor, an inducer of apoptosis or an inducer of differentiation. When expression of the gene of interest is to be repressed, the gene can encode a gene product which is or acts as an oncogene or an inhibitor of apoptosis. For example, the bcl-2 gene encodes an inhibitor of apoptosis.
More particularly, the invention is directed to a method of augmenting gene expression, especially of a tumor suppressor gene, a butyric acid-responsive gene or a fetal hemoglobin gene, by treating a host or host cells with an expression-enhancing amount of a compound of Formula (I). Preferably the host is a cancer patient. This method of the invention thus includes augmenting tumor suppressor gene expression in conjunction with ex vivo or in vivo gene therapy, i.e., the compound of the invention can be co-administered to the host during administration of gene therapy vectors or administration of the ex vivo transfected cells. Similarly, the compounds of the invention can be used to treat cells during the transfection step of ex vivo gene therapy. The hosts of the method therefore include cancer patients or other patients under going gene therapy. The host cells of the invention include hematopoietic cells such as stem cells and progenitor cells, e.g., or any other cell type used in ex vivo gene therapy.
Yet another embodiment of the invention is directed to a method of inducing tolerance to an antigen which comprises administering a therapeutically-effective amount of compound of Formula (I). Preferably the antigen is a self-antigen. For example, the self-antigen can be associated with an autoimmune disease such as systemic lupus erythromatosus, rheumatoid arthritis, multiple schlerosis, myasthenia gravis or diabetes. Alternatively tolerance can be induced to one or more antigens present on transplanted a organ or cells.
Yet further the invention is directed to a method for treating, preventing, or ameliorating protozoan infection in a subject which comprises administering to said subject an effective amount of a compound of Formula (I). The protozoan infections treatable in accordance with the invention include, but are not limited to, malaria, cryptosporidiosis, toxoplasmosis, or coccidiosis.
Still further the invention is directed to a method of inhibiting histone deacetylase in cells which comprises administering an effective amount of a compound of Formula (I) to said cells.
The invention is also directed to compounds represented by the formula:
wherein
R is C 2 -C 10 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, aryl or heteroaryl, any of which can be optionally substituted with halo, trifluoromethyl, hydroxy, alkoxy, cyano, nitro or carbonyl, wherein the heteroatom of said heteroaryl is oxygen or sulfur;
R 1 and R 2 are independently H, C 1 -C 10 alkyl, C 2 -C 10 alkenyl, or C 2 -C 10 alkynyl, any of which can be optionally substituted with halo, alkoxy, amino, trifluoromethyl, aryl or heteroaryl;
A is
R 3 is
R 4 , R 5 , R 6 and R 7 are independently H, alkyl or alkenyl;
B is aryl or heteroaryl, wherein the heteroatom of said heteroaryl is oxygen or sulfur;
m and n are independently 0 to 5;
the sum of m and n is 1 to 5;
p, q and r are independently 0 to 2; or
a pharmaceutically-acceptable salt thereof;
with the provisos that when R is selected from the group of 2-phenylethenyl moieties consisting of 2-phenylethenyl, 2-(alkylphenyl)ethenyl, 2-(nitrophenyl)ethenyl or 2-(halophenyl)ethenyl, then A and B taken together cannot be any of said moieties; and that when R is p-hydroxyphenyl, then A and B taken together cannot be 2-(3-hydroxy-4-methoxyphenyl)ethenyl.
In a preferred embodiment, the compounds of the invention are those of Formula (I), wherein m is 1 to 5; n is 0 to 5; and p is 0. In another preferred embodiment, R 2 is H. Still, more preferred are the compounds of Formula (I), wherein
R is n-propyl, benzyl, 3-(phenyl)propyl, 2-chloroethyl, 2-propenyl;
R 1 is H or alkyl;
R 3 is
R 6 and R 7 are independently H or alkyl; and
n, q and r are 0.
In a most preferred embodiment, the compounds used in this invention are cinnamoyloxymethyl butyrate; cinnamoyloxymethyl phenylacetate; cinnamoyloxymethyl 4-phenylbutyrate; 1-(cinnamoyl)oxyethyl phenylacetate; 1-(cinnamoyl)oxyethyl 4-phenylbutyrate; 3,4-dimethoxycinnamoyloxymethyl butyrate; or 1-(3,4-dimethoxycinnamoyl)oxyethyl butyrate.
Another embodiment of the present invention is drawn to pharmaceutical compositions comprising a therapeutically effective amount of a compound of Formula (I) and a pharmaceutically effective carrier or diluent.
A further embodiment of the present invention is directed to pharmaceutical compositions comprising a therapeutically effective amount of a combination of compound of Formula (I) with other anti-cancer or anti-neoplastic agents together with a pharmaceutically effective carrier or diluent.
DETAILED DESCRIPTION OF THE INVENTION
The compounds herein described may contain asymmetric centers and geometric isomers. All chiral, diastereomeric, and racemic forms are included in the present invention. Many geometric isomers of olefins and the like can also be present in the compounds described herein, and all such stable isomers are contemplated in the present invention.
By “stable compound” or “stable structure” is meant herein a compound that is sufficiently robust to survive isolation to a useful degree of purity from a reaction mixture, and formulation into an efficacious therapeutic agent.
As used herein, “alkyl” means both branched- and straight-chain, saturated aliphatic hydrocarbon groups having the specified number of carbon atoms. As used herein “lower alkyl” means an alkyl group having 1 to 5 carbon atoms. As used herein, “alkenyl” means hydrocarbon chains of either a straight or branched configuration and one or more unsaturated carbon-carbon bonds, such as ethenyl, propenyl, and the like. “Lower alkenyl” is an alkenyl group having 2 to 6 carbon atoms. As used herein, “alkynyl” means hydrocarbon chains of either a straight or branched configuration and one or more carbon-carbon triple bonds, such as ethynyl, propynyl and the like. “Lower alkynyl” is an alkynyl group having 2 to 6 carbon atoms. When the number of carbon atoms is not specified, then alkyl, alkenyl and alkynyl means lower alkyl, lower alkenyl and lower alkynyl, respectively.
As used herein, “aryl” includes “aryl” and “substituted aryl.” Thus “aryl” of this invention means any stable 6- to 14-membered monocyclic, bicyclic or tricyclic ring, containing at least one aromatic carbon ring, for example, phenyl, naphthyl, indanyl, tetrahydronaphthyl (tetralinyl) and the like. The presence of substitution on the aryl group is optional, but when present, the substituents can be halo, alkyl, alkoxy, hydroxy, cyano, nitro or trifluoromethyl. When present on R in Formula (I), then the aryl substituents do not include amino, acylamino or carbamoyl.
As used herein, the term “heteroaryl” includes “heteroaryl” and “substituted heteroaryl.” Thus “heteroaryl” of this invention means a stable 5- to 10-membered monocyclic or bicyclic heterocyclic ring which is aromatic, and which consists of carbon atoms and from 1 to 3 heteroatoms selected from the group consisting of N, O and S and wherein the nitrogen may optionally be quaternized, and including any bicyclic group in which any of the above-defined heteroaryl rings is fused to a benzene ring. The heteroaryl ring may be attached to its pendant group at any heteroatom or carbon atom which results in a stable structure. The presence of substitution on the heteroaryl group is optional and can be on a carbon atom, a nitrogen atom or other heteroatom if the resulting compound is stable and all the valencies of the atoms have been satisfied. When present, the substituents of the substituted heteroaryl groups are the same as for the substituted aryl groups and also include alkylammonium salts when the substituent is an alkyl group attached to the nitrogen atom of the heteroaryl ring. These quarternized ammonium salts include halides, hydrohalides, sulfates, methosulfates, methanesulfates, toluenesulfates, nitrates, phosphates, maleates, acetates, lactates or any other pharmaceutically acceptable salt. Examples of heteroaryl groups include, but are not limited to furanyl, thienyl, pyrrolyl, pyrazolyl, imidazolyl, tetrazolyl, benzofuranyl, benzothienyl, indolyl, indolenyl, quinolinyl, isoquinolinyl and benzimidazolyl.
When a heteroaryl group is present on R or B in Formula I, then the heterotoms can not be nitrogen. Similarly, if this same heteroaryl group has any substituents, the subsituents do not include amino, cyano, nitro, acylamino or carbamoyl, i.e., there can not be a nitrogen-containing substiuent.
As used herein, “aralkyl” and “heteroaralkyl” refer to an aryl or heteroaryl group attached to an alkyl group. The aryl and heteroaryl groups of this moiety can optionally be substituted in accordance with the definitions herein.
The term “substituted”, as used herein, means that one or more hydrogens on the designated atom are replaced with a selection from the indicated groups, provided that the designated atom's normal valency is not exceeded, and that the substitution results in a stable compound.
The substituents of the invention include, as indicated, halo, hydroxy, alkyl, alkoxy, amino, cyano, nitro, trifluoromethyl, aryl, heteroaryl, trialkylammonium and salts thereof. These groups can be substituents for alkyl, alkenyl, alkynyl,aryl, aralkyl, heteroaryl and heteroaralkyl groups as indicated in accordance with the invention. A “halo” group is a halogen, and includes fluoro, chloro, bromo and iodo groups. The term “alkoxy” refers to an alkyl group having at least one oxygen substituent represented by R-O-.
As used herein, “therapeutically-effective amount” refers to that amount necessary to administer to a host to achieve an anti-tumor effect; to induce differentiation and/or inhibition of proliferation of malignant cancer cells, benign tumor cells or other proliferative cells; to aid in the chemoprevention of cancer; to promote wound healing; to treat a gastrointestinal disorder; to treat a blood disorder or increase the hemoglobin content of blood; to modulate an immune response; to enhance recombinant gene expression; to modulate gene expression; to augment expression of tumor suppressor genes; to enhance insulin expression; to enhance chloride channel expression; to induce tolerance to an antigen; to treat, prevent or ameliorate protozoan infection; or to inhibit histone deacetylase in cells. Methods of determining therapeutically-effective amounts are well known.
When the therapeutic or effective amount of the compound is for treating, preventing or ameliorating cancer or other proliferative disorder, then that amount can be an amount effective to inhibit histone deacetylase in the subject, patient or cancerous cells. Similarly, when the therapeutic or effective amount of the compound is for treating, preventing, or ameliorating protozoan infection then that amount can be an amount effective to inhibit protozoan histone deacetylase in the subject, patient or cancerous cells.
As used herein, “pharmaceutically acceptable salts” refer to derivatives of the disclosed compounds that are modified by making acid or base salts. Examples include, but are not limited to, mineral or organic acid salts of basic residues such as amines; alkali or organic salts of acidic residues such as carboxylic acids, and the like. Pharmaceutically acceptable salts include, but are not limited to, hydrohalides, sulfates, methosulfates, methanesulfates, toluenesulfonates, nitrates, phosphates, maleates, acetates, lactates and the like.
Pharmaceutically-acceptable salts of the compounds of the invention can be prepared by reacting the free acid or base forms of these compounds with a stoichiometric or greater amount of the appropriate base or acid in water or in an organic solvent, or in a mixture of the two; generally, nonaqueous media like ether, ethyl acetate, ethanol, isopropanol, or acetonitrile are preferred. The salts of the invention can also be prepared by ion exchange, for example. Lists of suitable salts are found in Remington's Pharmaceutical Sciences , 17th ed., Mack Publishing Company, Easton, Pa., 1985, p. 1418, the disclosure of which is hereby incorporated by reference in its entirety.
The “pharmaceutical agents” for use in the methods of the invention related to the coadministration of compounds of Formula II and Formula III, include but are not limited to anticancer agents as well as differentiating agents. For example, the pharmaceutical agent can be a cytokine, an interleukin, an anti-cancer agent, a chemotherapeutic agent, an antibody, a conjugated antibody, an immune stimulant, an antibiotic, a hormone antagonist or a growth stimulant. The pharmaceutical agent can also be a cytotoxic agent. Cytotoxic agents include antiviral nucleoside antibiotics such as ganciclovir, acyclovir, and famciclovir. Cytotoxic agents can also include radiation therapy.
As used herein, the “chemotherapeutic agents” include but are not limited to alkylating agents, purine and pyrimidine analogs, vinca and vinca-like alkaloids, etoposide and etoposide-like drugs, corticosteroids, nitrosoureas, antimetabolites, platinum-based cytotoxic drugs, hormonal antagonists, anti-androgens and antiestrogens.
The “cytokines” for use herein include but are not limited to interferon, preferably α, β or γ interferon, as well as IL-2, IL-3, G-CSF, GM-CSF and EPO.
As used herein, an “immune stimulant” is a substance such as C. parvum or sarcolectin which stimulates a humoral or cellular component of the immune system.
The chemotherapeutic agents of the invention include but are not limited to tamoxifen, doxorubicin, L-asparaginase, dacarbazine, amascrine, procarbazine, hexamethylmelamine, mitoxantrone and gemcitabine.
SYNTHETIC METHODS
The compounds of the present invention can generally be prepared by any method known in the art. For example, the compounds of the invention can be made by reacting the acid B-A-COOH with a reagent of the formula
or by reacting the acid RCOOH with the reagent of the formula
in the presence of a base, where Y is a leaving group such as halogen, methanesulfonate or p-toulenesulfonate and R, R 1 , R 2 , A and B are as defined herein. The above reagents are readily prepared according to literature procedures, see for example, Nudelman et al., J. Med. Chem . 35:687-694, 1992, and Japanese patent 07033709 (1995). The base can be a trialkylamine, pyridine, an alkali metal carbonate or other suitable base. The reaction can be carried out in the presence or absence of an inert solvent. Suitable solvents include, for example, acetone, benzene, toluene, tetrahydrofuran, ethyl acetate, acetonitrile, dimethylformamide, dimethyl sulfoxide, chloroform, dioxan or 1,2-dichloroethane.
The procedures outlined above can be improved by one skilled in the art by, for instance, changing the temperature, duration, stoichiometry or other parameters of the reactions. Any such changes are intended to fall within the scope of this invention.
ACTIVITY
The activities of the compounds of the invention can be measured using generally-accepted techniques known to those skilled in the art consistent with the activity of interest. For example, the activity of compounds useful as differentiating agents can be measured using standard methodology of the nitro-blue tetrazolium reduction assay (e.g., Rabizadeh et al., FEBS Lett . 328:225-229, 1993; Chomienne et al., Leuk. Res . 10:631, 1986; and Breitman et al. in Methods for Serum - free Culture of Neuronal and Lymphoid Cells , Alan R. Liss, N.Y., p. 215-236, 1984 which are hereby incorporated by reference in their entirety) and as described below. This in vitro assay has been deemed to be predictive and in fact correlative with in vivo efficacy (Castaigne et al., Blood 76:1704-1709, 1990).
Another assay which is predictive of differentiating activity is the morphological examination for the presence of Auer rods and/or specific differentiation cell surface antigens in cells collected from treatment groups, as described in Chomienne et al., ( Blood 76:1710-1717, 1990 which is hereby incorporated by reference in its entirety) and as described below.
The compounds of the present invention also have anti-proliferative and anti-tumor activity. The anti-proliferation activity of compounds of the present invention can be determined by methods generally known to those skilled in the art. Generally-accepted assays for measuring viability and anti-proliferative activity are the trypan blue exclusion test and incorporation of tritiated thymidine, also as described by Chomienne, et al., above, which is incorporated herein by reference. Other assays which predict and correlate antitumor activity and in vivo efficacy are the human tumor colony forming assay described in Shoemaker et al., Can. Res . 45:2145-2153, 1985, and inhibition of telomerase activity as described by Hiyayama et al., J. Natl. Cancer Inst . 87:895-908, 1995, which are both incorporated herein by reference in their entirety. These assays are described in further detail below.
Cell Cultures
Human promyelocytic leukemia cells (HL-60), human pancreatic carcinoma cells (PaCa-2) and human breast adenocarcinoma cells, pleural effusion cells (MCF-7) can be cultured as follows. Cells are grown in RPMI media with 10% FCS, supplemented with 2 mM glutamine and incubated at 37° C. in a humidified 5% CO 2 incubator. Alternatively, cells can be grown in any other appropriate growth medium and conditions which supports the growth of the cell line under investigation. Viability can be determined by trypan blue exclusion. Cells are exposed to a test compound, cultures are harvested at various time points following treatment and stained with trypan blue.
Cellular Staining to Detect Differentiation
Lipid staining and/or immunochemical staining of casein can be used as a marker for cellular differentiation of breast cancer cells (Bacus et al., Md. Carcin . 3:350-362, 1990). Casein detection can be done by histochemical staining of breast cancer cells using a human antibody to human casein as described by Cheung et al., J. Clin. Invest . 75:1722-1728, which is incorporated by reference in its entirety.
Nitro-Blue Tetrazolium (NBT) Assay:
Cell differentiation of myeloid leukemia cells can be evaluated, for example, by NBT reduction activity as follows. Cell cultures are grown in the presence of a test compound for the desired time period. The culture medium is then brought to 0.1% NBT and the cells are stimulated with 400 mM of 12-O-tetradecanoyl-phorbol-13-acetate (TPA). After incubation for 30 min at 37° C., the cells are examined microscopically by scoring at least 200 cells. The capacity for cells to reduce NBT is assessed as the percentage of cells containing intracellular reduced black formazan deposits and corrected for viability.
Cell Surface Antigen Immunophenotyping
Cell surface antigen immunotyping can be conducted using dual-color fluorescence of cells gated according to size. The expression of a panel of antigens from early myeloid (CD33) to late myeloid can be determined as described in Warrell, Jr. et al., New Engl. J. Med . 324:1385-1392, 1992, which is incorporated by reference herein in its entirety.
Apoptosis Evaluation
Apoptosis can be evaluated by DNA fragmentation, visible changes in nuclear structure or immunocytochemical analysis of Bcl-2 expression.
DNA fragmentation can be monitored by the appearance of a DNA ladder on an agarose gel. For example, cellular DNA is isolated and analyzed by the method of Martin et al., J. Immunol ., 145:1859-1867, 1990 which is incorporated by reference herein in its entirety.
Changes in nuclear structure can be assessed, for example, by acridine orange staining method of Hare et al., J. Hist. Cyt ., 34:215-220, 1986 which is incorporated by reference herein in its entirety.
Immunological detection of Bcl-2 can be performed on untreated cells and cells treated with the test compound. HL-60 cells are preferred but other cell lines capable of expressing Bcl-2 can be used. Cytospins are prepared and the cells are fixed with ethanol. Fixed cells are reacted overnight at 4° C. with the primary monoclonal antibody, anti-Bcl-2 at a dilution of 1:50. Staining is completed to visualize antibody binding, for example, using Strep A-B Universal Kit (Sigma) in accordance with the manufacturer's instructions. Identically-treated cells which received no primary antibody can serve as a non-specific binding control. Commercial kits are also available and can be used for detecting apoptosis, for example, Oncor's Apop Tag®.
Modulation of Gene Expression
The levels of expression from oncogene and tumor suppressor genes can be evaluated by routine methods known in the art such as Northern blotting of RNA, immunoblotting of protein and PCR amplification.
Mouse Cancer Model
Compounds can be examined for their ability to increase the life span of animals bearing B16 melanomas, Lewis lung carcinomas and myelomonocytic leukemias as described in Nudelman et al., J. Med. Chem . 35:687-694, 1992, or Rephaeli et al., Int. J. Cancer 49:66-72, 1991, which are incorporated by reference herein in their entireties.
For example, the efficacy of compounds of the present invention in a leukemia model can be tested as follows: Balb/c mice are injected with WEHI cells and a test compound or control solution is administered the following day. The life span of the treated animals is compared to that of untreated animals.
The efficacy of compounds of the present invention on primary tumors can also be tested with subcutaneously implanted lung carcinoma or B16 melanoma by measuring the mass of the tumor at the site of implantation every two weeks in control and treated animals.
The efficacy of compounds in xenografts can be determined by implanting the human tumor cells subcutaneously into athymic mice. Human tumor cell lines which can be used include, but are not limited to, prostate carcinoma (human Pc-3 cells), pancreatic carcinoma (human Mia PaCa cells), colon adenocarcinoma (human HCT-15 cells) and mammary adenocarcinoma (human MX-1 cells). Treatment with control solution or a test compound of the invention begins, for example, when tumors are approximately 100 mg. Anti-tumor activity is assessed by measuring the delay in tumor growth, and/or tumor shrinking and/or increased survival of the treated animals relative to control animals.
Telomerase Activity
High levels of telomerase activity is associated with the high proliferation rate found in cancer cells. Compounds which inhibit telomerase activity results in inhibition of cancer cell growth and de-differentiation. Commercially available telomerase assays can thus be used to assess the anticancer activities of compounds on cancer cell lines.
Chemoprevention
The chemoprevention activity of the compounds of the invention can be determined in the two-stage mouse carcinogenesis model of Nishimo et al. (supra).
Assay of Compounds
Compounds of the invention, their salts or metabolites, can be measured in a biological sample by any method known to those skilled in the art of pharmacology, clinical chemistry or the like. Such methods for measuring these compounds are standard methods and include, but are not limited to high performance liquid chromatography (HPLC), gas chromatography (GC), gas chromatography mass spectroscopy (GC-MS), radioimmunoassay (RIA), and others.
Dosage and Formulation
The compounds of the present invention can be administered to a mammalian patient to treat cancer or in any other method of the invention which involves treating a patient by any means that produces contact of the active agent with the agent's site of action in the body of the subject. Mammalian patients include humans and domestic animals. The compounds of the invention can be administered by any conventional means available for use in conjunction with pharmaceuticals, either as individual therapeutic agents or in a combination of therapeutic agents. The compounds can be administered alone, but are generally administered with a pharmaceutical carrier selected on the basis of the chosen route of administration and standard pharmaceutical practice. The pharmaceutical compositions of the invention may be adapted for oral, parenteral, transdermal, transmucosal, rectal or intranasal administration, and may be in unit dosage form, as is well known to those skilled in the pharmaceutical art. The term “parenteral”, as used herein includes subcutaneous, intravenous, intramuscular, or intrasternal injection or infusion techniques.
The appropriate dosage administered in any given case will, of course, vary depending upon known factors, such as the pharmacodynamic characteristics of the particular agent and its mode and route of administration; the age, general health, metabolism, weight of the recipient and other factors which influence response to the compound; the nature and extent of the symptoms; the kind of concurrent treatment; the frequency of treatment; and the effect desired. A daily dosage of active ingredient can be expected to be about 10 to 10,000 milligrams per meter 2 of body mass (mg/m 2 ), with the preferred dose being 50-5,000 mg/m 2 body mass.
Dosage forms (compositions suitable for administration) contain from about 1 mg to about 1 g of active ingredient per unit. In these pharmaceutical compositions the active ingredient will ordinarily be present in an amount of about 0.5-95% by weight based on the total weight of the composition.
The active ingredient can be administered orally in solid or semi-solid dosage forms, such as for example hard or soft-gelatin capsules, tablets, and powders, or in liquid dosage forms, such as elixirs, syrups, disperse powders or granules, emulsions, and aqueous or oily suspensions. It can also be administered parenterally, in sterile liquid dosage forms. Other dosage forms include transdermal administration via a patch mechanism or ointment.
Compositions intended for oral use may be prepared according to any methods known to the art for the manufacture of pharmaceutical compositions and such compositions may contain one or more agents including sweetening agents, flavoring agents, coloring agents, and preserving agents in order to provide a pharmaceutically elegant and palatable preparation.
Tablets contain the active ingredient in admixture with non-toxic pharmaceutically acceptable excipients which are suitable for the manufacture of tablets. Such excipients may include, for example, inert diluents, such as calcium phosphate, calcium carbonate, sodium carbonate, sodium phosphate, or lactose; granulating disintegrating agents, for example, maize starch or alginic acid; binding agents, such as starch, gelatin, or acacia; and lubricating agents, for example, magnesium stearate, stearic acids or talc. Compressed tablets may be uncoated or may be sugar coated or film coated by known techniques to mask any unpleasant taste and protect the tablet from the atmosphere, or enteric coated for selective disintegration and adsorption in the gastrointestinal tract.
Hard gelatin capsules or liquid filled soft gelatin capsules contain the active ingredient and inert powdered or liquid carriers, such as, but not limited to calcium carbonate, calcium phosphate, kaolin, lactose, lecithin starch, cellulose derivatives, magnesium stearate, stearic acid, arachis oil, liquid paraffin, olive oil, pharmaceutically-accepted synthetic oils and other diluents suitable for the manufacture of capsules. Both tablets and capsules can be manufactured as sustained release-products to provide for continuous release of medication over a period of hours.
Aqueous suspensions contain the active compound in admixture with excipients suitable for the manufacture of aqueous suspensions. Such excipients are suspending agents, e.g., sodium carboxymethylcellulose, methylcellulose, hydroxypropylmethylcellulose, sodium alginate, polyvinylpyrrolidone, gum tragacanth, and gum acacia; dispersing or wetting agents, such as a naturally occurring phosphatide, e.g., lecithin, or condensation products of an alkylene oxide with fatty acids, for example of polyoxyethylene stearate, or a condensation products of ethylene oxide with long chain aliphatic alcohols, e.g., heptadecaethyleneoxycetanol, or condensation products of ethylene oxide with partial esters derived from fatty acids and a hexitol, e.g., polyoxyethylene sorbitol monooleate, or a condensation product of ethylene oxide with partial esters derived from fatty acids and hexitol anhydrides, e.g., polyoxyethylene sorbitan monooleate. The aqueous suspensions can also contain one or more preservatives, for example ethyl or n-propyl p-hydroxybenzoate, one or more coloring agents, one or more flavoring agents, and one or more sweetening agents, such as sucrose, saccharin, or sodium or calcium cyclamate.
Dispersable powders and granules suitable for preparation of an aqueous suspension by the addition of water provide the active ingredient in admixture with a dispersing or wetting agent, suspending agent and one or more preservatives. Suitable dispersing or wetting agents and suspending agents are exemplified by those already mentioned above. Additional excipients, for example, sweetening, flavoring, and coloring agents, can also be present.
Syrups and elixirs can be formulated with sweetening agents, such as glycerol, sorbitol or sucrose. Such formulations may also contain a demulcent, a preservative and flavoring and coloring agents.
The pharmaceutical compositions can be in the form of a sterile injectable preparation, for example, as a sterile injectable aqueous suspension. This suspension can be formulated according to the known art using-those suitable dispersing or wetting agents and suspending agents which have been mentioned above. The sterile injectable preparation can also be a sterile injectable solution or suspension in a nontoxic parenterally-acceptable diluent or solvent, for example, as a solution in 1,3-butanediol.
In general, water, a suitable oil, saline, aqueous dextrose (glucose), polysorbate and related sugar solutions, emulsions, such as Intralipid® (Cutter Laboratories, Inc., Berkley Calif.) and glycols such as propylene glycol or polyethylene glycols are suitable carriers for parenteral solutions. Antioxidizing agents, such as but not limited to sodium bisulfite, sodium sulfite, or ascorbic acid, either alone or combined, are suitable stabilizing agents. Also used can be citric acid and its salts and sodium EDTA. In addition, parenteral solutions can contain preservatives, such as but not limited to benzalkonium chloride, methyl- or propyl-paraben, and chlorobutanol.
The pharmaceutical compositions of the present invention also include compositions for delivery across cutaneous or mucosal epithelia including transdermal, intranasal, sublingual, buccal, and rectal administration. Such compositions may be part of a transdermal device, patch, topical formulation, gel, etc., with appropriate excipients. Thus, the compounds of the present invention can be compounded with a penetration-enhancing agent such as 1-n-dodecylazacyclopentan-2-one or the other penetration-enhancing agents disclosed in U.S. Pat. Nos. 3,991,203 and 4,122,170 which are hereby incorporated by reference in their entirety to describe penetration-enhancing agents which can be included in the transdermal or intranasal compositions of this invention.
Suitable pharmaceutical carriers are described in Remington's Pharmaceutical Sciences , Mack Publishing Company, a standard reference text in this field, which is incorporated herein by reference in its entirety.
Various modifications of the invention in addition to those shown and described herein will be apparent to those skilled in the art from the foregoing description. Such modifications are also intended to fall within the scope of the appended claims.
The foregoing disclosure includes all the information deemed essential to enable those skilled in the art to practice the claimed invention. Because the cited patents or publications may provide further useful information these cited materials are hereby incorporated by reference in their entirety.
EXAMPLE 1
Synthesis of 3,4-Dimethyoxycinnamoyloxymethyl Butyrate (DiMeOCOMB)
To a stirred solution of 3,4-dimethoxycinnamic acid (5 g, 24 mmol) and chloromethyl butyrate (3.3 g, 1 eq.) in dry dimethylformamide (20 mL), under nitrogen was dropwise added triethylamine (4 mL, 2.3 g, 1.2 eq). The reaction mixture was heated to 70° C. overnight; during that time a large amount of precipitate formed and TLC (ethyl acetate:hexane 1:2) showed that all the acid had reacted. The precipitate was filtered and washed with ethyl acetate. The filtrate was partitioned between water and ethyl acetate. The aqueous phase was washed with a small amount of ethyl acetate, and the combined organic phase was washed with water (3×), 5% solution of NaHCO 3 (2×), and brine (2×), dried with MgSO 4 and evaporated to give crude product as a yellow heavy oil (5.7 g). The crude product was chromatographed on silica gel (200 g, ethyl acetate:hexane 1:3) to give the pure product (second fraction) as a colorless oil (4.7 g, 64% yield).
EXAMPLE 2
Synthesis of Cinnamoyloxymethyl Butyrate (COMB)
To a stirred solution of cinnamic acid (10 g, 67 mmol) and chloromethyl butyrate (9.5 g, 1 eq) in dry dimethylformamide (25 mL) under nitrogen was dropwise added triethylamine (12 mL, 8.5 g, 1.2 eq). The reaction mixture was heated at 70° C. for 3 h; during that time a large amount of precipitate formed and TLC (ethyl acetate:hexane 1:4) showed that all the acid has reacted. The precipitate was filtered and washed with ethyl acetate. The filtrate was partitioned between water and ethyl acetate. The aqueous phase was washed with a small amount of ethyl acetate, and the combined organic phase was washed with water (3×), 5% solution of NaHCO 3 (2×) and brine (2×) dried with MgSO 4 and evaporated to give the crude product as an orange oil (15 g), which was distilled at 150° C./0.1-0.2 mm Hg. The pure product was obtained as a colorless oil (12 g, 72% yield).
EXAMPLE 3
Additional Compounds of the Invention
The compounds of Table 1 are those of Formula (I) having the specified groups and can be synthesized in a manner similar to that described above using the appropriate reagents.
TABLE 1
Additional Formula (I) Compounds of the Invention
R
R 1
R 2
A
B
C 6 H 5 CH 2 —
CH 3
H
ClCH 2 CH 2 CH 2 —
CH 3
C 2 H 5
—C≡C—
CH 3 O—CH 2 —C≡C—CH 2 —
CCl 3
H
—CH═CH—C≡C—
C 4 H 9
H
—CH═CH—
CH 3 CH═CH
H
CF 3 CH 2 CH 2 —
C 6 H 5
H
C 3 H 7
CH 3
H
—CH═CH—
C 3 H 7 —
C 3 H 7
H
—CH═CH—
C 3 H 7 —
C 3 H 7
CH 3
—C≡C—
CH 2 ═CHCH 2 —
C 9 H 19
H
—C≡C—CH═CH—
C 3 H 7 —
C 2 H 5
H
C 6 H 5 —CH 2 —
H
H
—CH═CH—
C 6 H 5 —CH 2 —
CH 3
H
—CH═CH
C 6 H 5 —CH 2 CH 2 CH 2
H
H
—CH═CH—
C 6 H 5 —CH 2 CH 2 CH 2
CH 3
H
—CH═CH—
C 6 H 5 —CH 2 —
H
H
—CH═CH—
C 6 H 5
C 6 H 5 —CH 2 —
CH 3
H
—CH═CH
C 6 H 5
C 6 H 5 —CH 2 CH 2 CH 2
H
H
—CH═CH—
C 6 H 5
C 6 H 5 —CH 2 CH 2 CH 2
CH 3
H
—CH═CH—
C 6 H 5
EXAMPLE 4
Inhibition of Cancer Cell Proliferation Assessed by the SRB Assay
The inhibition of cell proliferation was measured in the indicated cancer cell lines using the sulforhodamine B (SRB) assay as described by Monks et al., 1991 , J. Natl. Can. Inst . 83:757-766. The SRB assay is used to screen for anti-cancer drugs. The inhibitory activities of COMB and DiMeOCOMB are compared to α-methylcinnamic acid (MeCA) and 2-methyl-3-phenylpropionic acid (MePPA) in Table 2. The table provides the dosage of each compound (in mM) which inhibited fifty percent (IC 50 ) or ninety percent (IC 90 ) of proliferation when calculated using the Chou Analysis' Median Effective Dose equation.
TABLE 3
Inhibitory Activity of COMB and DiMeCOMB
DiMeOCOMB
Cell
MeCA
MePPA
COMB
Butyrate
Line
IC 50
IC 90
IC 50
IC 90
IC 50
IC 90
IC 50
IC 90
CFPAC
1.938
>4.000
3.545
>4.0
0.150
0.237
0.308
3.570
HL-60
2.602
>4.000
>4.000
>4.0
0.443
>4.000
0.203
0.248
HT29
3.962
>4.000
>4.000
>4.0
0.349
0.492
0.406
0.798
LOX IMVI
3.356
>4.000
>4.000
>4.0
0.197
1.914
0.772
0.978
MCF7
>4.000
>4.000
>4.000
>4.0
0.196
>4.000
0.301
0.466
NCI-H23
3.271
>4.000
>4.000
>4.0
0.182
0.249
0.785
>4.000
NCI-H522
1.979
3.818
>4.000
>4.0
0.189
0.249
0.752
1.366
OVCAR-5
3.731
>4.000
>4.000
>4.0
0.367
0.500
1.464
1.892
PC-3
>4.000
>4.000
>4.000
>4.0
0.203
>4.000
1.441
1.874
SF-295
>4.000
>4.000
>4.000
>4.0
0.197
>4.000
0.764
0.977
(a) All concentrations are in mM.
EXAMPLE 5
Inducing Differentiation
Cancer cell differentiation was evaluated in a human leukemia cell line by changes in expression of myelocytic maturation marker CD11b.
The level of CD11b was measured on HL-60 cells by flow cytometry using a monoclonal antibody (MAb) against CD11b in a standard indirect immunofluorescence assay. Cells were cultured for 3 days with media or the indicated concentration of DiMeOCOMB. Cultured cells were collected by centrifugation, resuspended at 10 6 cells per 20μ RPMI+10% FCS and incubated with MAb for 30 min at 40° C. The cells were washed twice in cold PBS+10k FCS and incubated with a 1:20 dilution of FITC-conjugated F(ab′) 2 fragment of rabbit anti-mouse IgG for 20-30 min at 40° C. in the dark. After washing the cells twice in cold PBS+10% FCS, the flow cytometry was performed. The results are shown in Table 3.
TABLE 3
Expression of CD11b
Concentration (μM)
% CD11b Cells
0
12.2
50
87.5
100
88.6
203
90.4 | The invention relates to methods of modulating gene expression in a hematopoietic cell or augmenting hematopoiesis in a host, as well as methods of treating, preventing, or ameliorating disorders affecting hematopoiesis level in a host, by administering to the host or the hematopoietic cell an effective amount of a compound of formula (I). | 69,716 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a continuation-in-part of the earlier patent application Ser. No. 07/560,604 filed Jul. 31, 1990 now abandoned.
THE FIELD OF THE INVENTION
The present invention relates to a Gardening Information Kit to be used in supplying the amateur or the advanced gardener with all relevant information regarding dates, planting, transplanting, growing, watering, fertilizing, spraying, harvesting and storing a wide variety of plants and vegetables.
BACKGROUND OF THE INVENTION
The Gardening information Kit was created due to a need for information while in the garden without reading volumes of reference material or bringing these books into the garden.
The home gardener grows many different plants and vegetables all with different protection, spacing and care needs. It is difficult if not impossible to commit all this information to memory. Therefore, the gardener will probably have to refer to his reference material. Some gardeners only have seed packets, some have an extensive library. Most of the seed packets do not provide the appropriate information needed for the many tasks to complete harvest. It is difficult to bring these reference books into the garden without some damage. After the gardener reads his reference material, how does he easily bring this information into the garden. Many questions go unanswered.
When to plant is probably one of the most important questions that a gardener asks. Most gardeners try to push the season and plant as early as possible. If the gardener plants frost sensitive vegetables too early, destruction of the crop will be the result. He must know what to plant and when. A tool was needed that could give him the correct information about when to plant for any latitude in the country or internationally, be user friendly and at the same time provide a calendar.
There has been a recent increase in public awareness of the health benefits of organic gardening, especially vegetable gardening (defined as gardening without the use of petro-chemically based herbicides, fungicides, pesticides, and fertilizers that have been associated with the causes of many health problems including cancer). The organic method biologically enhances the soil, avoids pollution and creates an environment which is healthy for the gardener and his family. The awareness level of protecting us from the use of dangerous pesticides has even reached the petro-chemical industry. Even Ortho, a subsidiary of Cheveron, now producing a line of organic products. It certainly means that there is a base of consumers who prefer the organic to the petro-chemical products.
Many people subscribe to the use of organic gardening techniques in home vegetable gardening. However, many people who try home vegetable gardening, especially first timers, are not sufficiently experienced and have not been exposed to the methods that are actually simple. There is also a preconceived notion that organic gardening methods are difficult and result in poor quality produce. Most gardeners are not aware that there are easy alternatives to the petro-chemical industry's herbicides, fungicides and pesticides. In fact most garden pests can be managed by natural, barrier, botanical and biologically commercially available products. There have been many books written on the subject of gardening, but few on organic gardening as compared to the plethora of information available. Education is needed in order to change over to organic gardening. This can be a deterrent to practicing organic gardening.
Some of the more important questions that concern gardeners are, ie.: which vegetables are prone to be killed by the frost, which can be planted for Fall harvest, or which need to be started indoors. The ability of this kit to sort the data cards without reading each individual card to answer these kinds of questions is invaluable. A kit was needed that could sort out specific questions and pieces of information.
The summary of the above problems are as follows: how does one summarize and transfer the information with an organic orientation, how does one avoid bringing books into the garden, how does one manipulate planting dates for the gardener's specific locale, how does one sort information quickly and how does one minimize the waisting of time. The Gardening information Kit solves these problems with its two components.
The kit combines 2 elements which serve different functions yet when combined together they create a complete source of information for every aspect of growing the target vegetable or plant including dates and the hows of germination, starting seedlings indoors, transplanting, planting, watering, spraying, harvesting and storage.
1. It summarizes information concerning each vegetable as completely and as clearly as possible, free from clutter and in a form which the gardener can use effortlessly.
2. It gives the home gardener the ability to have a user friendly sorting system similar to a data base at his fingertips right i the garden. In the present embodiment there are 44 specific pieces of information available, presented on the vertical sides, but not limited to, of a standard sized paper, for example. Categories for the storing stations are determined by the subject matter of the kit, ie. vegetables or perrenial flowers.
3. The circular calendar calculator gives the gardener the ability to manipulate specific dates for his specific locale and for specific vegetables and/or plants. It can be used to determine when to start seedlings, when to plant directly into the garden, when to transplant seedlings, when to discontinue planting, when is the expected harvest date, and to determine if there is enough time for another crop before Fall frost. This is all executed by gardeners anywhere in the country. The only piece of information that the gardener needs to provide are the dates of the first and last frost.
4. It addresses the principal aims of organic agriculture as adopted by the International Federation of Organic Agriculture Movements.
U.S. Pat. No. 3,316,668, issued to Rogers on May 2, 1967, disclosed an adjustable garden chart which is a device for correlating information recorded on a plurality of indicia bearing strips. Although Rogers' design allows one to retrieve information regarding the growing of certain crops, He uses strips and reels which can be moved together or independently. His device could also be applied to finding the constellations int he various skies throughout the year.
U.S. Pat. No. 4,248,458, issued to Brody on Feb. 3, 1981, is a device used in the field of horse racing. Its object is to randomly select the horses for Win, Place, Show, Daily Double, Quinella, Perfecta, and/or Trifecta without the seu of publications and authoritative sources. This device uses three concentric circles with indicia; however, it also contains a face plate with "equicircumferentially distributed presentation openings" for the above betting selections and also contains a bottom cover for a total of five wheels. The indicia which can be seen thru the face plate openings are only used after the three wheels have been arbitrarily moved by manipulating them on the reverse side. It is then that the bettor turns this device to the obverse side to reveal the numbers of the individual participants. The information indicia contained in the embodiment of the circular calendar calculator responds to the specific problem of planting dates (from the earliest planting date to discontinuation). Not only does this kit manipulate multiple indicia, but unlike Brody, it acts as an informational source. Six distinct items can be determined by the circular calendar calculator unlike Brody's which only reveal one, the numbers of participants matched with the type of betting possibilities.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a kit of gardening information which is user friendly in that it provides substantially all of the information necessary for the home gardener to successfully raise vegetables.
It is a further object of the present invention to provide a kit having several components which the gardener can selectively use on site, in the garden, in any weather and the allows immediate access to all the information necessary, in a timely fashion, to accomplish those tasks necessary for the successful growth and harvest of crops and/or plants.
It is still another object of the present invention to provide a Gardening Information Kit that contain several components which are useful both independently and in combination to successfully plan, plant, raise and harvest vegetables.
The subject invention comprises a two component system, namely (1) data cards with information concerning growing information for a variety of vegetables, which data cards can be mechanically sorted according to particular categories of information contained on the face sorting card; (2) a circular calendar calculator wheel to determine specific information regarding optimum task execution dates throughout the calendar year.
While it is contemplated that the gardening information kit will aid the organic gardener, the system can also be used for all types of gardening, i.e. vegetables, fruit and flower, whether or not organic methods are utilized.
BRIEF DESCRIPTION OF THE DRAWINGS
The present 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 obverse of a data card of the present invention;
FIG. 2 is a plan view of a calendar calculator wheel of the present invention;
FIGS. 3-5 are elevational views of the outter, middle and inner discs forming the calendar calculator wheel of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is a Gardening Information Kit designed to readily provide the novice or advanced gardener with all relevant information needed to plan, plant, grow, maintain, harvest and store a wide variety of plants and vegetables. It would be here noted that the terms "plans" and "vegetables" are being used in a generic sense and would include all the things an average homeowner might want to grow on his property, such as herbs, flowers, shrubs, trees and ornamental plants, as well as plants and vegetables normally growth for human consumption. It should also be noted that the words "major category" are assigned the meaning of the grouplings of indicia in the main body of the data card and that the words "sorting category" are assigned the meaning of information that can be retrieved by inserting the sorting tool into the stations of holes 22 and slots 20. The subject kit has two primary components, namely (1) a plurality of data cards, as shown in FIG. 1; (2) at least one calendar calculator wheel, as shown in FIG. 2;
Turning first to the data cards 10 of FIG. 1, the data card is preferably of sufficient size to hold a lot of data, for example 8.5×11" or conventional letter size. The data is preferable a laminate formed by plastic coatings on both sides of a printed sheet of paper or printed on plastic laminate similar to a credit card. This provides a certain amount of rigidity and durability for the data card which is necessary for the task of repeated sorting.
Information is provided on both the obverse and reverse of each data card according to several major categories of information, such as but not limited to "Temperatures and Germination", "Dates", "Apperance", "Planting and Transplanting Procedures", "Planting Methods", "Thinning", "Soil", etc. as illustrated on the obverse in FIG. 1. There may be as many as 18 or more major categories or groupings of informational indicia depending on need. Each data card 10 contains information specific to the plant or vegetable that is described and/or illustrated on the top of the data card, Tomatoes in the illustrated example.
In order to manually sort the data cards 10 by any one of a number of sorting categories, each data card is provided with sorting means 18 formed by a plurality of holes 22 and slots 20 arrayed along at least one marginal edge 24 of each data card. Besides being able to sort the various families or groups of vegetables, this system allows for selecting, ie: "All cool weather vegetables", "Seedlings started indoors", "Vegetables that tolerate shade", "Vegetables that are heavy feeders", or "Vegetables that are attacked by the squash vine borer", etc. Many other sorting categories may be included or substituted. The patterning of holes and slots is unique for each data card but the positioning stations of all holes and slots on all cards is identical. All positions or stations will be numbered and a face card with the numbered indicia will be provided. Thus, to select any particular piece of sortable information or specific group of data cards, one looks up the corresponding number, inserts an elongated blunt instrument, such as a needle or rod (not shown) into the selected numbered position and passes the sorting tool through the aligned holes 22 and slots 20 of the data cards 10 making up the stack. It is assumed that the desired edge 24 is in the top most position. The needle or rod is then moved vertically out of the stack to pass out of the slots of those data cards which are not in the selected sorting category while carrying along the data cards having holes, as opposed to slots, at the selected position or station.
For example, if someone desired all vegetables that need to be started indoors, they would first check to make sure that all the data cards 10 were facing in the same direction, look up the correct number on the face card, then they would insert an instrument, such as the above mentioned elongated blunt needle, into the select numbered position of a stack of data cards. The remaining data cards which do not apply to the selection are left behind in the stack until needed. When it comes time to return the data cards to the stack, it is not necessary to locate their original position in the stack or reinsert the data cards in any particular order. The used data cards can simply be placed, facing the same direction, in any order in the stack as the sorting system of the present invention allows them to be recovered any time form any order. This unique sorting system of the present invention allows access to a large quantity of information which has been presorted, while being easy to manipulate since the order of the data cards is not a factor in recovering the desired data cards.
The above identified categories are only illustrative of the major and/or sorting categories contemplated by this invention. Many other categories could be included or substituted.
FIG. 2 illustrates a circular calendar calculator wheel 12. The wheel 12 is preferably made of at least semi-rigid plastic or plastic coated material with a water-proof surface bearing the calendar informational indicia. Preferably the wheel 12 is of such a size to be able to contain information to be easily read, however, small enough so as not to make the calculator cumbersome to handle. Preferably, the outside dimension of the wheel 12 will be less than 81/2". The outter edge of the middle wheel 28 will be of such dimension as not to hide the indicia of the outer wheel 26 and some of the radiating spokes This allows the user of this tool to align the radiating spokes of the various wheels. The outter dimension of the inner wheel 30 should be less that the inside dimension of the most inner set of numbers 34, 36 of the middle wheel 28.
This calculator wheel 12 consists of three concentric and coaxially rotatable mounted circular calculator discs; (1) the outside disc 26; (2) the middle disc 28; and (3) the inner disc 30 all relatively rotatable secured together by hub 32. It is contemplated that there could be a calculator wheel for each general family or grouping of vegetable or plants.
The outside disc 26 FIG. 5 carries notations relating to the calendar year. It is preferably broken down into fifty-two accurate and equal portions which are in 7 day increments. The indicia which correlates to these lines will follow the calendar year, starting on January 1 and continues as follows: January 8, 15, 22, 29, February 5, 12, 19, 26, etc.
The middle disc 28 FIG. 4 carries several sets of numbers in two concentric configurations for ease of calculation. The inner set of numbers 34 and 36 substantially completely encircling the middle disc 28 and spaced inwardly from its parameter. Each arcuate set of numbers 34 and 36 are designated plus (+) and Minus (-) numbers going clockwise and counterclockwise, respectively, from two nearly opposite zero points. These sets of numbers represent weeks before (-) and after (+) the Spring 40 and Fall 38 frost dates. Additional outer number sets 42 and 44 help in determining the number of days to a particular desired event, ie. days to harvest or the number of frost free days until the Fall frost. This is accomplished by selecting either the list 42 or 44 and then placing that zero of the selected list on the starting date which is found on the outter disc 26. Both of these sets of numbers are located on the outer perimeter of disc 28. The number set 42 ranges from 0 weeks to 16 weeks (ie. 0 1, 2, 3, . . . 16). The number set 44 ranges from 0 days to 126 days in 7 day increments (ie. 0, 7, 14, 21 . . . 126). Each number for both sets 42, 44 corresponds to the spokes of the wheel. Also in the middle wheel 28 around the hub 32 occurs the name of the grouping or family 46 that is contained on this individual wheel. Concentrically radiating inward from 34 and 36 are the names of the individual vegetables 48 contained on this individual wheel. Directly next to the names of the vegetables are numbers 50 which indicate either the number of days from transplant to harvest or the number of days from direct seeding to harvest. To the right and in line are shaded areas 52 which indicate the range of time when the vegetable may first be placed in the ground either as a seed or transplant and the end of this shaded area to the extreme right indicates the number of weeks to cease planting after the Spring frost or the number of weeks to cease planting before the first Fall frost.
These areas will be shaded different colors or marked in some way as to indicate the difference between direct planting and those vegetables that may be stared as seedlings outside the garden, ie. in a greenhouse. It is in the latter case that the inner wheel 30 will be used.
In the preferred embodiment the inner wheel 30 FIG. 3 is made of transparent material with sufficient thickness as to be able to withstand multiple manipulations. Fifty - two lines radiate from the hub 32 as was mentioned above. One of the lines will appear thicker than the others and will labeled the Transplant Date 54 and marked with zero. Moving to the left each line will be numbered 56 starting with 1 and continue, for example to ten. These numbers which correspond to time units (weeks) will be used in conjunction with the shaded areas 52 of the middle circle 28. Hatched areas 58 on the transparent inner circle 30 will indicate the number of weeks before transplant that the gardener is to start his seedlings indoors (ie. for Tomatoes it's 6-8 weeks before transplant). Vegetables that are only to be planted outside will not have a hatched area 58 on the transparent inner circle 30 directly over the corresponding vegetable 48.
The following is a description of how to determine the date for starting, seedlings, when to transplant and when to expect the beginning of the harvest ie. Tomatoes. It is assumed that the last killing frost will occur before April 30th. The gardener wants to place out the seedlings as early as possible without the danger of frost.
1. Place the Spring 40 zero under the date April 30th, aligning the spokes of the wheels 26 and 28.
2. Align the Transplant Date line 54 of the inner wheel 30 with the extreme left edge of the shaded area 52 on the middle wheel 28. This is the earliest this gardener can plant safely for this area.
3. Look for the vegetable name 48 (Tomato) and follow the radius around to the left until the hatched area 58 of the inner circle 30.
4. Note that the hatched area 58 falls between the numbers of six and eight 56 on the inner circle 30. Continue following these radiating lines up to the dates of the outter circle 26. Seedlings may be started indoors between the dates of March 5th and March 19th when transplanted on April 30th and will be six to eight weeks old.
5. The name of the vegetable 48 Tomato has the number seventy-four 50. This number indicates the average number of days from transplant to harvest.
6. Align the zero 44 of the middle circle 28 to the date April 30th, the transplanting date. The number seventy-four falls between the numbers seventy and seventy-seven 44 printed of 28. The expected start of the tomato harvest is approximately July 13.
In use the wheel is designed to instantly yield the following information
1. The date (or dates) on which one should start seedlings based on the last frost date.
2. The date (or dates) on which one should transplant the seedlings.
3. The date (or dates) on which one should plant directly in the garden.
4. The average number of days from seed to harvest or from transplant to harvest.
5. The approximate dates one should harvest the vegetables.
6. The possibility of succession planting may be determined by calculating the approximate number of frost free days between the harvest of the first crop and the harvest of the second crop.
It is contemplated that, in use, the device of the present invention will provide the gardener will accurate information, easily readable, and in a format that will be rewarding to his efforts. Since information derived from this calendar calculator wheel is based on local frost dates which are supplied by the gardener, the wheel is substantially universal in application without regard to the planting zone.
While there has been described what are at present considered to be 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 invention and it is therefore aimed too cover all such changes and modifications so as to fall within the true spirit and scope of the invention. | A Garden information Kit has two elements which provide all the information necessary for successful planting, growing and harvesting of crops. The first element is a set of data cards both carrying information and having means to easily sort the cards carrying the desired information. The second element is a calendar calculation wheel used to determine when certain events are to be executed. | 23,060 |
CROSS REFERENCE TO RELATED APPLICATION
This is a continuation in part of pending U.S. application Ser. No. 09/141,659, filed Aug. 28, 1998, the teachings of which are here in incorporated by reference.
BACKGROUND OF THE INVENTION
This invention relates to certain Group 3, 4 or Lanthanide metal complexes possessing two metal centers and to polymerization catalysts obtained therefrom. In one form this invention relates to such metal complexes per se. In another embodiment of the claimed invention, the complexes can be activated to form catalysts for the polymerization of olefins. Also included in the invention are processes for preparing such complexes and methods of using the catalysts in addition polymerizations.
Biscyclopentadienyl Group 4 transition metal complexes in which the metal is in the +4, +3 or +2 formal oxidation state, and olefin polymerization catalysts formed from such by combination with an activating agent, for example, alumoxane or ammonium borate, are well known in the art. Thus, U.S. Pat. No. 3,242,099 describes the formation of olefin polymerization catalysts by the combination of biscyclopentadienyl metal dihalides with alumoxane. U.S. Pat. No. 5,198,401 discloses tetravalent biscyclopentadienyl Group 4 transition metal complexes and olefin polymerization catalysts obtained by converting such complexes into cationic forms in combination with a non-coordinating anion. Particularly preferred catalysts are obtained by the combination of ammonium borate salts with the biscyclopentadienyl titanium, zirconium or hafnium complexes. Among the many suitable complexes disclosed are bis(cyclopentadienyl)zirconium complexes containing a diene ligand attached to the transition metal through σ-bonds where the transition metal is in its highest formal oxidation state. R. Mülhaupt, et al., J. Organomet. Chem., 460,191 (1993), reported on the use of certain binuclear zirconocene derivatives of dicyclopentadienyl-1,4-benzene as catalysts for propylene polymerization.
Constrained geometry metal complexes, including titanium complexes, and methods for their preparation are disclosed in U.S. application Ser. No. 545,403, filed Jul. 3,1990 (EP-A-416,815); U.S. Pat. Nos. 5,064,802, 5,374,696, 5,055,438, 5,057,475, 5,096,867, and 5,470,993.
Metal complexes of the constrained geometry type containing two metal centers joined by means of a dianionic ligand separate from and unconnected to the ligand groups in such complexes that contain delocalized π-electrons, are previously taught, but not exemplified, in U.S. Pat. No. 5,055,438.
SUMMARY OF THE INVENTION
The present invention relates to dinuclear metal complexes corresponding to the formula:
wherein:
M and M′ are independently Group 3, 4, 5, 6, or Lanthanide metals;
L, L′, W, and W′, independently, are divalent groups having up to 50 nonhydrogen atoms and containing an aromatic π-system through which the group is bound to M, said L and W also being bound to Z, and said L′ and W′ also being bound to Z′;
Z and Z′ independently are trivalent moieties comprising boron or a member of Group 14 of the Periodic Table of the Elements, and optionally also comprising nitrogen, phosphorus, sulfur or oxygen, said Z and Z′ having up to 20 atoms not counting hydrogen;
X and T independently each occurrence are anionic ligand groups having up to 40 atoms exclusive of the class of ligands containing an aromatic π-system through which the group is bound to M or M′, or optionally two X groups or two T groups together form a C 4-40 conjugated or nonconjugated diene optionally substituted with one or more hydrocarbyl, silyl, halocarbyl, or halohydrocarbyl groups;
X′ and T′ independently each occurrence are neutral ligating compound having up to 20 atoms other than neutral diene compounds;
Q is a divalent anionic ligand group bound to both Z and Z′, said Q having up to 20 nonhydrogen atoms;
w and w′ are independently 0 or 1;
x and t are independently integers from 0 to 3, selected to provide charge balance; and
x′ and t′ are independently numbers from 0 to 3.
Additionally according to the present invention there is provided a composition of matter useful as an addition polymerization catalyst comprising:
1) at least one dinuclear metal complex (I) as previously disclosed, and
2) one or more activating cocatalysts,
the molar ratio of 1) to 2) being from 1:10,000 to 100:1, or
the reaction product formed by converting 1) to an active catalyst by use of an activating technique.
Further additionally according to the present invention there is provided a process for polymerization of one or more addition polymerizable monomers comprising contacting said monomer or a mixture of said monomers with a catalyst comprising the aforementioned composition of matter.
The invented catalyst compositions allow the preparation of mixtures of polymers from a single monomer or mixture of monomers thereby forming directly a polymer blend in the reactor. This result is accentuated where different metals, different metal valencies or different ligand groups attached to the two metal centers are employed. Alternatively, the invention allows for increased incorporation of long chain branching in a polymer formed from a single monomer, especially ethylene, or a mixture of monomers, due to selection of one metal center adapted to forming oligomeric products terminated by vinyl functionality in combination with a second metal center adapted to form high molecular weight polymers or adapted to long chain α-olefin incorporation into a polymer.
DETAILED DESCRIPTION
All reference to the Periodic Table of the Elements herein shall refer to the Periodic Table of the Elements, published and copyrighted by CRC Press, Inc., 1989. Also, any reference to a Group or Groups shall be to the Group or Groups as reflected in this Periodic Table of the Elements using the IUPAC system for numbering groups.
In all of the forgoing and succeeding embodiments of the invention, desirably, when w and w′ are both 1, two X and two T groups together are a diene or substituted diene. Further preferred compounds correspond to the formula:
wherein
Z, Z′, M, M′, X, X′, T, T′, w, w′, x, x′, t, and t′ are as previously defined;
Cp and Cp′, independently are cyclic C 5 R′ 4 groups bound to Z or Z′ respectively and bound to M or M′ respectively by means of delocalized π-electrons, wherein R′, independently each occurrence, is hydrogen, hydrocarbyl, silyl, halo, fluorohydrocarbyl, hydrocarbyloxy, hydrocarbylsiloxy, N,N-di(hydrocarbylsilyl)amino, N-hydrocarbyl-N-silylamino, N,N-di(hydrocarbyl)amino, hydrocarbyleneamino, di(hydrocarbyl)phosphino, hydrocarbylsulfido; or hydrocarbyloxy-substituted hydrocarbyl, said R′ having up to 20 nonhydrogen atoms, and optionally, two such R′ substituents may be joined together thereby causing Cp or Cp′ to have a fused ring structure; and
Q is a linear or cyclic hydrocarbylene, or silane group or a nitrogen, oxygen, or halo substituted derivative thereof, said Q having up to 20 nonhydrogen atoms.
More preferred metal coordination complexes according to the present invention correspond to the formula:
wherein:
R′ each occurrence is hydrogen, hydrocarbyl, silyl, germyl, halo, cyano, halohydrocarbyl, hydrocarbyloxy, hydrocarbylsiloxy, di(hydrocarbylsilyl)amino, hydrocarbylsilylamino, di(hydrocarbyl)amino, hydrocarbyleneamino, di(hydrocarbyl)phosphino, hydrocarbylsulfido; or hydrocarbyloxy-substituted hydrocarbyl, said R′ having up to 20 nonhydrogen atoms, and optionally, two R′ groups together form a divalent derivative thereof connected to adjacent positions of the cyclopentadienyl ring thereby forming a fused ring structure, or R′ in one occurrence per cyclopentadienyl system is a covalent bond to Q;
Z″ independently each occurrence is a trivalent group selected from SiR*, CR*, SiR*SiR* 2 , CR*CR* 2 , CR*SiR* 2 , CR* 2 SiR*, or GeR*; wherein R* each occurrence is independently hydrogen, hydrocarbyl, silyl, halogenated alkyl, or halogenated aryl, said R* having up to 12 non-hydrogen atoms;
Z′″ independently each occurrence is —Z″Y′—, wherein:
Y′ is —O—, —S—, —NR″—, —PR″—, —OR″, or —NR″ 2 (and with respect to —OR″ and —NR″ 2 , one bond is a dative bond through the available electron pair),
wherein R″ is hydrogen, hydrocarbyl, silyl, or silylhydrocarbyl of up to 20 atoms not counting hydrogen;
M and M′ independently are Ti, Zr or Hf;
X and T, independently are halide, hydrocarbyl or two X groups together or two T groups together are a conjugated diene group, said X and T groups having up to 20 atoms not counting hydrogen; and
Q is a linear or cyclic hydrocarbylene group, silane group, or silyl substituted hydrocarbylene group, or a nitrogen, oxygen, or halo substituted derivative thereof, said Q having up to 20 atoms not counting hydrogen.
Preferably, R′ independently each occurrence is hydrogen, hydrocarbyl, silyl, fluorophenyl, hydrocarbyloxy, N,N-di(hydrocarbyl)amino, hydrocarbyleneamino, or hydrocarbyloxy-substituted hydrocarbyl, said R′ having up to 20 non-hydrogen atoms, or two adjacent R′ groups are joined together forming part of a fused ring system. Most preferably, R′ is hydrogen, methyl, ethyl, propyl, butyl, pentyl, hexyl, (including where appropriate all isomers), cyclopentyl, cyclohexyl, norbornyl, benzyl, phenyl, N,N-di(methyl)amino, pyrrolyl, pyrrolidinyl, or two R′ groups are linked together, the entire C 5 R′ 4 group thereby forming an indenyl, tetrahydroindenyl, fluorenyl, tetrahydrofluorenyl, indacenyl, or octahydrofluorenyl group, or a C 1-6 hydrocarbyl-substituted, N,N-di(methyl)amino-substituted, pyrrolyl, or pyrrolidinyl-substituted derivative thereof.
Examples of suitable X or T groups for all of the foregoing structural depictions of the invention include single atomic groups including hydride or halide, as well as multi-atomic groups such as hydrocarbyl, hydrocarbyloxy, dihydrocarbylamido (including cyclic hydrocarbyleneamido groups) and halo, amino, or phosphino substituted derivatives thereof, said multi-atomic groups containing up to 20 nonhydrogen atoms. Specific examples include chloride, methyl, benzyl, allyl, N,N-dimethylamido, pyrrolinado, pyrrolidinado, (N,N-dimethylamino)benzyl, phenyl, methoxide, ethoxide, isopropoxide and isobutoxide. Most preferably X and T are chloride, methyl, N,N-dimethylamido, or benzyl.
In the embodiments wherein two X or wherein two T groups together form a diene group or substituted diene group, such group may form a α-complex with M or M′ or the diene may form a σ-complex with M or M′. In such complexes M and M′ are preferably Group 4 metals, most preferably Ti. In such complexes in which the diene is associated with the metal as a α-complex, the metal is in the +4 formal oxidation state and the diene and metal together form a metallocyclopentene. In such complexes in which the diene is associated with the metal as a π-complex, the metal is in the +2 formal oxidation state, and the diene normally assumes a s-trans configuration or an s-cis configuration in which the bond lengths between the metal and the four carbon atoms of the conjugated diene are nearly equal. The dienes of complexes wherein the metal is in the +2 formal oxidation state are coordinated via π-complexation through the diene double bonds and not through a metallocycle resonance form containing σ-bonds. The nature of the bond is readily determined by X-ray crystallography or by NMR spectral characterization according to the techniques of Yasuda, et al., Organometallics, 1, 388 (1982), (Yasuda I); Yasuda, et al. Acc. Chem. Res., 18, 120 (1985), (Yasuda II); Erker, et al. , Adv. Organomet. Chem., 24, 1 (1985)(Erker, et al. (I)); and U.S. Pat. No. 5,198,401. By the term “π-complex” is meant both the donation and back acceptance of electron density by the ligand are accomplished using ligand π-orbitals. Such dienes are referred to as being π-bound. It is to be understood that the present complexes may be formed and utilized as mixtures of the π-complexed and σ-complexed diene compounds.
The formation of the diene complex in either the π or σ state depends on the choice of the diene, the specific metal complex and the reaction conditions employed in the preparation of the complex. Generally, terminally substituted dienes favor formation of π-complexes and internally substituted dienes favor formation of σ-complexes. Especially useful dienes for such complexes are compounds that do not decompose under reaction conditions used to prepare the complexes of the invention. Under subsequent polymerization conditions, or in the formation of catalytic derivatives of the present complexes, the diene group may undergo chemical reactions or be replaced by another ligand.
Examples of suitable dienes (two X or T groups taken together) include: butadiene, 1,3-pentadiene, 1,3-hexadiene, 2,4-hexadiene, 1,4-diphenyl-1,3-butadiene, 3-methyl-1,3-pentadiene, 1,4-dibenzyl-1,3-butadiene, 1,4-ditolyl-1,3-butadiene, and 1,4-bis(trimethylsilyl)-1,3-butadiene.
Examples of the preferred metal complexes according to the present invention include compounds wherein R′ is methyl, ethyl, propyl, butyl, pentyl, hexyl, (including all isomers of the foregoing where applicable), cyclododecyl, norbornyl, benzyl, phenyl, Q is 1,2-ethanediyl, 1,4-butanediyl, 1,6-hexanediyl or silane, Z″ is hydrocarbylsilane, most preferably methylsilanetriyl; and the cyclic delocalized π-bonded group is cyclopentadienyl, tetramethylcyclopentadienyl, indenyl, tetrahydroindenyl, 2-methylindenyl, 2,3-dimethylindenyl, 2-methyl-4-phenylindenyl, 3-N,N-dimethylaminoindenyl, 3-(pyrrolyl)inden-1-yl, 3-(pyrrolidinyl)inden-1-yl, fluorenyl, tetrahydrofluorenyl, indacenyl or octahydrofluorenyl group; M and M′ are titanium or zirconium in the +2 or +4 formal oxidation state.
Examples of the foregoing more further preferred dinuclear complexes are of the formula:
wherein
M is titanium or zirconium;
q is an integer from 2 to 10;
R′ is methyl or all R′ groups collectively with the cyclopentadienyl group form a 2,3,4,6-tetramethylinden-1-yl, 3-(N-pyrrolidinyl)inden-1-yl, or a 2-methyl-4-phenylinden-1-yl group; and
X and T, independently each occurrence, are chloride, methyl, benzyl or 2 X groups or two T groups together form a 1,4-diphenyl-1,3-butadiene or 1,3-pentadiene group.
Specific examples of the foregoing metal complexes include:
Titanium Complexes:
1,2-bis[(1-N-(t-butyl)amido)-1-methyl-1-(tetramethylcyclopentadien-diyl)silantitanium dichloride]ethane,
1,6-bis[(1-N-(t-butyl)amido)-1-methyl-1-(tetramethylcyclopentadien-diyl)silantitanium dichloride]hexane,
1,2-bis[(1-N-(t-butyl)amido)-1-methyl-1-(3-(1-pyrrolidinyl)-1H-inden-1-diyl)silantitanium dichloride]ethane,
1,6-bis[(1-N-(t-butyl)amido)-1-methyl-1-(3-(1-pyrrolidinyl)-1H-inden-1-diyl)silantitanium dichloride]hexane,
1,2-bis[(1-N-(t-butyl)amido)-1-methyl-1-(2,3,4,6-tetramethylinden-1-diyl)silantitanium dichloride]ethane,
1,6-bis[(1-N-(t-butyl)amido)-1-methyl-1-(2,3,4,6-tetramethylinden-1-diyl)silantitanium dichloride]hexane,
1,2-bis[(1-N-(t-butyl)amido)-1-methyl-1-(2-methyl-4-phenylinden-1-diyl)silantitanium dichloride]ethane,
1,6-bis[(1-N-(t-butyl)amido)-1-methyl-1-(2-methyl-4-phenylinden-1-diyl)silantitanium dichloride]hexane,
1,2-bis[(1-N-(t-butyl)amido)-1-methyl-1-(tetramethylcyclopentadien-diyl)silantitanium dimethyl]ethane,
1,6-bis[(1-N-(t-butyl)amido)-1-methyl-1-(tetramethylcyclopentadien-diyl)silantitanium dimethyl]hexane,
1,2-bis[(1-N-(t-butyl)amido)-1-methyl-1-(3-(1-pyrrolidinyl)-1H-inden-1-diyl)silantitanium dimethyl]ethane,
1,6-bis[(1-N-(t-butyl)amido)-1-methyl-1-(3-(1-pyrrolidinyl)-1H-inden-1-diyl)silantitanium dimethyl]hexane,
1,2-bis[(1-N-(t-butyl)amido)-1-methyl-1-(2,3,4,6-tetramethylinden-1-diyl)silantitanium dimethyl]ethane,
1,6-bis[(1-N-(t-butyl)amido)-1-methyl-1-(2,3,4,6-tetramethylinden-1-diyl)silantitanium dimethyl]hexane,
1,2-bis[(1-N-(t-butyl)amido)-1-methyl-1-(2-methyl-4-phenylinden-1-diyl)silantitanium dimethyl]ethane,
1,6-bis[(1-N-(t-butyl)amido)-1-methyl-1-(2-methyl-4-phenylinden-1-diyl)silantitanium dimethyl]hexane,
1,2-bis[(1-N-(t-butyl)amido)-1-methyl-1-(tetramethylcyclopentadien-diyl)silantitanium dibenzyl]ethane,
1,6-bis[(1-N-(t-butyl)amido)-1-methyl-1-(tetramethylcyclopentadien-diyl)silantitanium dibenzyl]hexane,
1,2-bis[(1-N-(t-butyl)amido)-1-methyl-1-(3-(1-pyrrolidinyl)-1H-inden-1-diyl)silantitanium dibenzyl]ethane,
1,6-bis[(1-N-(t-butyl)amido)-1-methyl-1-(3-(1-pyrrolidinyl)-1H-inden-1-diyl)silantitanium dibenzyl]hexane,
1,2-bis[(1-N-(t-butyl)amido)-1-methyl-1-(2,3,4,6-tetramethylinden-1-diyl)silantitanium dibenzyl]ethane,
1,6-bis[(1-N-(t-butyl)amido)-1-methyl-1-(2,3,4,6-tetramethylinden-1-diyl)silantitanium dibenzyl]hexane,
1,2-bis[(1-N-(t-butyl)amido)-1-methyl-1-(2-methyl-4-phenylinden-1-diyl)silantitanium dibenzyl]ethane,
1,6-bis[(1-N-(t-butyl)amido)-1-methyl-1-(2-methyl-4-phenylinden-1-diyl)silantitanium dibenzyl]hexane,
1,2-bis[(1-N-(t-butyl)amido)-1-methyl-1-(tetramethylcyclopentadien-diyl)silantitanium (II) 1,4-diphenyl-1-3-butadiene]ethane,
1,6-bis[(1-N-(t-butyl)amido)-1-methyl-1-(tetramethylcyclopentadien-diyl)silantitanium (II) 1,4-diphenyl-1-3-butadiene]hexane,
1,2-bis[(1-N-(t-butyl)amido)-1-methyl-1-(3-(1-pyrrolidinyl)-1H-inden-1-diyl)silantitanium (II) 1,4-diphenyl-1-3-butadiene]ethane,
1,6-bis[(1-N-(t-butyl)amido)-1-methyl-1-(3-(1-pyrrolidinyl)-1H-inden-1-diyl)silantitanium (II) 1,4-diphenyl-1-3-butadiene]hexane,
1,2-bis[(1-N-(t-butyl)amido)-1-methyl-1-(2,3,4,6-tetramethylinden-1-diyl)silantitanium (II) 1,4-diphenyl-1-3-butadiene]ethane,
1,6-bis[(1-N-(t-butyl)amido)-1-methyl-1-(2,3,4,6-tetramethylinden-1-diyl)silantitanium (II) 1,4-diphenyl-1-3-butadiene]hexane,
1,2-bis[(1-N-(t-butyl)amido)-1-methyl-1-(2-methyl-4-phenylinden-1-diyl)silantitanium (II) 1,4-diphenyl-1-3-butadiene]ethane,
1,6-bis[(1-N-(t-butyl)amido)-1-methyl-1-(2-methyl-4-phenylinden-1-diyl)silantitanium (II) 1,4-diphenyl-1-3-butadiene]hexane,
1,2-bis[(1-N-(t-butyl)amido)-1-methyl-1-(tetramethylcyclopentadien-diyl)silantitanium (II) 1,3-pentadiene]ethane,
1,6-bis[(1-N-(t-butyl)amido)-1-methyl-1-(tetramethylcyclopentadien-diyl)silantitanium (II) 1,3-pentadiene]hexane,
1,2-bis[(1-N-(t-butyl)amido)-1-methyl-1-(3-(1-pyrrolidinyl)-1H-inden-1-diyl)silantitanium (II) 1,3-pentadiene]ethane,
1,6-bis[(1-N-(t-butyl)amido)-1-methyl-1-(3-(1-pyrrolidinyl)-1H-inden-1-diyl)silantitanium (II) 1,3-pentadiene]hexane,
1,2-bis[(1-N-(t-butyl)amido)-1-methyl-1-(2,3,4,6-tetramethylinden-1-diyl)silantitanium (II) 1,3-pentadiene]ethane,
1,6-bis[(1-N-(t-butyl)amido)-1-methyl-1-(2,3,4,6-tetramethylinden-1-diyl)silantitanium (II) 1,3-pentadiene]hexane,
1,2-bis[(1-N-(t-butyl)amido)-1-methyl-1-(2-methyl-4-phenylinden-1-diyl)silantitanium (II) 1,3-pentadiene]ethane, and
1,6-bis[(1-N-(t-butyl)amido)-1-methyl-1-(2-methyl-4-phenylinden-1-diyl)silantitanium (II) 1,3-pentadiene]hexane.
Zirconium Complexes:
1,2-bis[1,1-bis(tetramethylcyclopentadiendiyl)-1-methylsilanzirconium dichloride]ethane,
1,6-bis[1,1-bis(tetramethylcyclopentadiendiyl)-1-methylsilanzirconium dichloride]hexane,
1,2-bis[1,1-bis(3-(1-pyrrolidinyl)-1-H-inden-1-diyl)-1-methylsilanzirconium dichloride]ethane,
1,6-bis[1,1-bis(3-(1-pyrrolidinyl)-1-H-inden-1-diyl)-1-methylsilanzirconium dichloride]hexane,
1,2-bis[1,1-bis(2,3,4,6-tetramethyl)-1-H-inden-1-diyl)-1-methylsilanzirconium dichloride]ethane,
1,6-bis[1,1-bis(2,3,4,6-tetramethyl)-1-H-inden-1-diyl)-1-methylsilanzirconium dichloride]hexane,
1,2-bis[1,1-bis(2-methyl-4-phenyl)-1-H-inden-1-diyl)-1-methylsilanzirconium dichloride]ethane,
1,6-bis[1,1-bis(2-methyl-4-phenyl)-1-H-inden-1-diyl)-1-methylsilanzirconium dichloride]hexane,
1,2-bis[1,1-bis(tetramethylcyclopentadiendiyl)-1-methylsilanzirconium dimethyl]ethane,
1,6-bis[1,1-bis(tetramethylcyclopentadiendiyl)-1-methylsilanzirconium dimethyl]hexane,
1,2-bis[1,1-bis(3-(1-pyrrolidinyl)-1-H-inden-1-diyl)-1-methylsilanzirconium dimethyl]ethane,
1,6-bis[1,1-bis(3-(1-pyrrolidinyl)-1-H-inden-1-diyl)-1-methylsilanzirconium dimethyl]hexane,
1,2-bis[1,1-bis(2,3,4,6-tetramethyl)-1-H-inden-1-diyl)-1-methylsilanzirconium dimethyl]ethane,
1,6-bis[1,1-bis(2,3,4,6-tetramethyl)-1-H-inden-1-diyl)-1-methylsilanzirconium dimethyl]hexane,
1,2-bis[1,1-bis(2-methyl-4-phenyl)-1-H-inden-1-diyl)-1-methylsilanzirconium dimethyl]ethane,
1,6-bis[1,1-bis(2-methyl-4-phenyl)-1-H-inden-1-diyl)-1-methylsilanzirconium dimethyl]hexane,
1,2-bis[1,1-bis(tetramethylcyclopentadiendiyl)-1-methylsilanzirconium dibenzyl]ethane,
1,6-bis[1,1-bis(tetramethylcyclopentadiendiyl)-1-methylsilanzirconium dibenzyl]hexane,
1,2-bis[1,1-bis(3-(1-pyrrolidinyl)-1-H-inden-1-diyl)-1-methylsilanzirconium dibenzyl]ethane,
1,6-bis[1,1-bis(3-(1-pyrrolidinyl)-1-H-inden-1-diyl)-1-methylsilanzirconium dibenzyl]hexane,
1,2-bis[1,1-bis(2,3,4,6-tetramethyl)-1-H-inden-1-diyl)-1-methylsilanzirconium dibenzyl]ethane,
1,6-bis[1,1-bis(2,3,4,6-tetramethyl)-1-H-inden-1-diyl)-1-methylsilanzirconium dibenzyl]hexane,
1,2-bis[1,1-bis(2-methyl-4-phenyl)-1-H-inden-1-diyl)-1-methylsilanzirconium dibenzyl]ethane,
1,6-bis[1,1-bis(2-methyl-4-phenyl)-1-H-inden-1-diyl)-1-methylsilanzirconium dibenzyl]hexane,
1,2-bis[1,1-bis(tetramethylcyclopentadiendiyl)-1-methylsilanzirconium (II) 1,4-diphenyl-1-3-butadiene]ethane,
1,6-bis[1,1-bis(tetramethylcyclopentadiendiyl)-1-methylsilanzirconium (II) 1,4-diphenyl-1-3-butadiene]hexane,
1,2-bis[1,1-bis(3-(1-pyrrolidinyl)-1-H-inden-1-diyl)-1-methylsilanzirconium (II) 1,4-diphenyl-1-3-butadiene]ethane,
1,6-bis[1,1-bis(3-(1-pyrrolidinyl)-1-H-inden-1-diyl)-1-methylsilanzirconium (II) 1,4-diphenyl-1-3-butadiene]hexane,
1,2-bis[1,1-bis(2,3,4,6-tetramethyl)-1-H-inden-1-diyl)-1-methylsilanzirconium (II) 1,4-diphenyl-1-3-butadiene]ethane,
1,6-bis[1,1-bis(2,3,4,6-tetramethyl)-1-H-inden-1-diyl)-1-methylsilanzirconium (II) 1,4-diphenyl-1-3-butadiene]hexane,
1,2-bis[1,1-bis(2-methyl-4-phenyl)-1-H-inden-1-diyl)-1-methylsilanzirconium (II) 1,4-diphenyl-1-3-butadiene]ethane, and
1,6-bis[1,1-bis(2-methyl-4-phenyl)-1-H-inden-1-diyl)-1-methylsilanzirconium (II) 1,4-diphenyl-1-3-butadiene]hexane.
In general, the complexes of the present invention can be prepared by combining the dimetallated or diGrignard compound derived from the group Q in the resulting complex, with the precursor complex or mixture of complexes in a suitable noninterfering solvent at a temperature from −100° C. to 300° C., preferably from −78 to 130° C., most preferably from −10 to 120° C. More particularly, the complexes can be prepared by lithiating a compound of the formula: HCp—Z—Q—Z—CpH, such as 1,2-ethane (bisinden-1-yl)methylchlorosilane), reacting the resulting dimetallated compound with 2 equivalents of an amine, preferably t-butylamine, and reacting the resulting product with a metal halide such as titanium or zirconium tetrachloride or titanium or zirconium trichloride, and optionally oxidizing the resulting metal complex. Similarly, the bis(bridged metal complexes) are prepared by lithiating a compound of the formula: (HCp)(HW)Z—Q—Z(WH)(CpH), such as 1,2-ethanebis[bis(inden-1-yl)methylsilane] and reacting the resulting product directly with the metal halide salt. The corresponding hydrocarbyl or diene derivative may be prepared by known exchange with the metal hydrocarbyl or conjugated diene under reducing conditions. Alternatively, the desired bimetal dihydrocarbyl complex can be directly formed by reaction with a titanium or zirconium tetraamide, especially titanium tetra(N,N-dimethylamide) or zirconium tetra(N,N-dimethylamide), under ring formation conditions, followed by reaction with excess aluminum trialkyl to form the desired dialkyl derivative. Modifications of the foregoing preparation procedure to prepare alternative compound of the invention may be employed by the skilled artisan without departing from the scope of the present invention.
Suitable reaction media for the formation of the complexes are aliphatic and aromatic hydrocarbons and halohydrocarbons, ethers, and cyclic ethers. Examples include straight and branched-chain hydrocarbons such as C 4-12 alkanes and mixtures thereof; cyclic and alicyclic hydrocarbons such as cyclohexane, cycloheptane, methylcyclohexane, methylcycloheptane, and mixtures thereof; aromatic and hydrocarbyl-substituted aromatic compounds such as benzene, toluene, xylene, and C 1-4 dialkyl ethers, C 1-4 dialkyl ether derivatives of (poly)alkylene glycols, and tetrahydrofuran. Mixtures of the foregoing list of suitable solvents are also suitable.
The recovery procedure involves separation of the resulting alkali metal or alkaline earth metal salt and devolatilization of the reaction medium. Extraction into a secondary solvent may be employed if desired. Alternatively, if the desired product is an insoluble precipitate, filtration or other separation technique may be employed.
The complexes are rendered catalytically active by combination with an activating cocatalyst or by use of an activating technique. Suitable activating cocatalysts for use herein include polymeric or oligomeric alumoxanes, especially methylalumoxane, triisobutyl aluminum modified methylalumoxane, or diisobutylalumoxane; strong Lewis acids (the term “strong” as used herein defines Lewis acids which are not Bronsted acids), such as C 1-30 hydrocarbyl substituted Group 13 compounds, especially tri(hydrocarbyl)aluminum- or tri(hydrocarbyl)boron compounds and halogenated derivatives thereof, having from 1 to 10 carbons in each hydrocarbyl or halogenated hydrocarbyl group, more especially perfluorinated tri(aryl)boron compounds, and most especially tris(pentafluorophenyl)borane or 1,4-tetrafluorophenylene {bis(bis(pentafluorophenyl)borane}; nonpolymeric, ionic, compatible, noncoordinating, activating compounds (including the use of such compounds under oxidizing conditions); and combinations thereof. The foregoing activating cocatalysts and activating techniques have been previously taught with respect to different metal complexes in the following references: EP-A-277,003, U.S. Pat. Nos. 5,153,157, 5,064,802, 5,321,106, 5,721,185, 5,425,872, 5,350,723, WO97-35893 (equivalent to U.S. Ser. No. 08/818,530, filed Mar. 14, 1997), and U.S. provisional application No. 60/054586, filed Sep. 15, 1997.
Combinations of strong Lewis acids, especially the combination of a trialkyl aluminum compound having from 1 to 4 carbons in each alkyl group and a halogenated tri(hydrocarbyl)boron compound having from 1 to 10 carbons in each hydrocarbyl group, especially tris(pentafluorophenyl)borane; further combinations of such strong Lewis acid mixtures with a polymeric or oligomeric alumoxane; and combinations of a single strong Lewis acid, especially tris(pentafluorophenyl)borane with a polymeric or oligomeric alumoxane are especially desirable activating cocatalysts.
The technique of bulk electrolysis involves the electrochemical oxidation of the metal complex under electrolysis conditions in the presence of a supporting electrolyte comprising a noncoordinating, inert anion. In the technique, solvents, supporting electrolytes and electrolytic potentials for the electrolysis, are used such that electrolysis byproducts that would render the metal complex catalytically inactive are not substantially formed during the reaction. More particularly, suitable solvents are materials that are liquids under the conditions of the electrolysis (generally temperatures from 0 to 100° C.), capable of dissolving the supporting electrolyte, and inert. “Inert solvents” are those that are not reduced or oxidized under the reaction conditions employed for the electrolysis. It is generally possible in view of the desired electrolysis reaction to choose a solvent and a supporting electrolyte that are unaffected by the electrical potential used for the desired electrolysis. Preferred solvents include difluorobenzene (ortho, meta, or para isomers), dimethoxyethane, and mixtures thereof.
The electrolysis may be conducted in a standard electrolytic cell containing an anode and cathode (also referred to as the working electrode and counter electrode respectively). Suitable materials of construction for the cell are glass, plastic, ceramic and glass coated metal. The electrodes are prepared from inert conductive materials, by which are meant conductive materials that are unaffected by the reaction mixture or reaction conditions. Platinum or palladium are preferred inert conductive materials. Normally an ion permeable membrane such as a fine glass frit separates the cell into separate compartments, the working electrode compartment and counter electrode compartment. The working electrode is immersed in a reaction medium comprising the metal complex to be activated, solvent, supporting electrolyte, and any other materials desired for moderating the electrolysis or stabilizing the resulting complex. The counter electrode is immersed in a mixture of the solvent and supporting electrolyte. The desired voltage may be determined by theoretical calculations or experimentally by sweeping the cell using a reference electrode such as a silver electrode immersed in the cell electrolyte. The background cell current, the current draw in the absence of the desired electrolysis, is also determined. The electrolysis is completed when the current drops from the desired level to the background level. In this manner, complete conversion of the initial metal complex can be easily detected.
Suitable supporting electrolytes are salts comprising a cation and an inert, compatible, noncoordinating anion, A − . Preferred supporting electrolytes are salts corresponding to the formula
G + A −
wherein:
G + is a cation which is nonreactive towards the starting and resulting complex; and
A − is a noncoordinating, compatible anion.
Examples of cations, G + , include tetrahydrocarbyl substituted ammonium or phosphonium cations having up to 40 nonhydrogen atoms. A preferred cation is the tetra-n-butylammonium cation.
During activation of the complexes of the present invention by bulk electrolysis the cation of the supporting electrolyte passes to the counter electrode and A − migrates to the working electrode to become the anion of the resulting oxidized product. Either the solvent or the cation of the supporting electrolyte is reduced at the counter electrode in equal molar quantity with the amount of oxidized metal complex formed at the working electrode. Preferred supporting electrolytes are tetrahydrocarbylammonium salts of tetrakis(perfluoro-aryl)borates having from 1 to 10 carbons in each hydrocarbyl group, especially tetra-n-butylammonium tetrakis(pentafluorophenyl)borate.
Suitable activating compounds useful as a cocatalyst in one embodiment of the present invention comprise a cation which is a Bronsted acid capable of donating a proton, and an inert, compatible, noncoordinating, anion, A − . Preferred anions are those containing a single coordination complex comprising a charge-bearing metal or metalloid core which anion is capable of balancing the charge of the active catalyst species (the metal cation) which is formed when the two components are combined. Also, said anion should be sufficiently labile to be displaced by olefinic, diolefinic and acetylenically unsaturated compounds or other neutral Lewis bases such as ethers or nitrites. Suitable metals include, but are not limited to, aluminum, gold and platinum. Suitable metalloids include, but are not limited to, boron, phosphorus, and silicon. Compounds containing anions which comprise coordination complexes containing a single metal or metalloid atom are, of course, well known and many, particularly such compounds containing a single boron atom in the anion portion, are available commercially. Therefore, said single boron atom compounds are preferred.
Preferably such cocatalysts may be represented by the following general formula:
(L*−H) d + (A d− )
wherein:
L* is a neutral Lewis base;
(L*−H) + is a Bronsted acid;
A d− is a noncoordinating, compatible anion having a charge of d−, and
d is an integer from 1 to 3.
More preferably A d− corresponds to the formula:
[M′ k+ Q′ n′ ] d−
wherein:
k is an integer from 1 to 3;
n′ is an integer from 2 to 6;
n′−k=d;
M′ is an element selected from Group 13 of the Periodic Table of the Elements; and
Q′ independently each occurrence is an hydride, dialkylamido, halide, alkoxide, aryloxide, hydrocarbyl, or halosubstituted-hydrocarbyl radical, said Q′ having up to 20 carbons with the proviso that in not more than one occurrence is Q′ halide.
In a more preferred embodiment, d is one, that is the counter ion has a single negative charge and corresponds to the formula A − . Activating cocatalysts comprising boron which are particularly useful in the preparation of catalysts of this invention may be represented by the following general formula:
[L*−H] + [BQ″ 4 ] −
wherein:
L* is as previously defined;
B is boron in a valence state of 3; and
Q″ is a fluorinated C 1-20 hydrocarbyl group.
Most preferably, Q″ is in each occurrence a fluorinated aryl group, especially a pentafluorophenyl group.
Illustrative, but not limiting examples of boron compounds which may be used as an activating cocatalyst in the preparation of the improved catalysts of this invention are tri-substituted ammonium salts such as:
trimethylammonium tetrakis(pentafluorophenylborate,
dimethylanilinium tetrakis(pentafluorophenylborate,
dimethyltetradecylammonium tetrakis(pentafluorophenylborate,
dimethyhexadecylammonium tetrakis(pentafluorophenylborate,
dimethyloctadecylammonium tetrakis(pentafluorophenylborate,
methylbis(tetradecyl)ammonium tetrakis(pentafluorophenylborate,
methylbis(hexadecyl)ammonium tetrakis(pentafluorophenylborate,
methylbis(octadecyl)ammonium tetrakis(pentafluorophenylborate, and mixtures thereof.
Another suitable ion forming, activating cocatalyst comprises a salt of a cationic oxidizing agent and a noncoordinating, compatible anion represented by the formula:
(Ox e+ ) d (A d− ) e
wherein:
Ox e+ is a cationic oxidizing agent having a charge of e+;
e is an integer from 1 to 3; and
A d− , and d are as previously defined.
Examples of cationic oxidizing agents include: ferrocenium, hydrocarbyl-substituted ferrocenium, Ag + , or Pb +2 . Preferred embodiments of A d− are those anions previously defined with respect to the Bronsted acid containing activating cocatalysts, especially tetrakis(pentafluorophenyl)borate.
Another suitable ion forming, activating cocatalyst comprises a compound which is a salt of a carbenium ion and a noncoordinating, compatible anion represented by the formula:
ĉ + A −
wherein:
ĉ − is a C 1-20 carbenium ion; and
A − is as previously defined. A preferred carbenium ion is the trityl cation, that is triphenylcarbenium.
The foregoing activating technique and ion forming cocatalysts are also preferably used in combination with a tri(hydrocarbyl)aluminum compound having from 1 to 4 carbons in each hydrocarbyl group, an oligomeric or polymeric alumoxane compound, or a mixture of a tri(hydrocarbyl)aluminum compound having from 1 to 4 carbons in each hydrocarbyl group and a polymeric or oligomeric alumoxane.
The molar ratio of catalyst/cocatalyst employed preferably ranges from 1:10,000 to 100:1, more preferably from 1:5000 to 10:1, most preferably from 1:1000 to 1:1. In a particularly preferred embodiment of the invention the cocatalyst can be used in combination with a C 3-30 trihydrocarbyl aluminum compound, C 3-30 (hydrocarbyoloxy)dihydrocarbylaluminum compound, or oligomeric or polymeric alumoxane. Which aluminum compounds are employed for their beneficial ability to scavenge impurities such as oxygen, water, and aldehydes from the polymerization mixture. Preferred aluminum compounds include C 2-6 trialkyl aluminum compounds, especially those wherein the alkyl groups are ethyl, propyl, isopropyl, n-butyl, isobutyl, pentyl, neopentyl, or isopentyl, and methylalumoxane, modified methylalumoxane and diisobutylalumoxane. The molar ratio of aluminum compound to metal complex is preferably from 1:10,000 to 1000:1, more preferably from 1:5000 to 100:1, most preferably from 1:100 to 100:1.
The catalysts may exist as cationic derivatives of the dinuclear complexes, as zwitterionic derivatives thereof, or in an as yet undetermined relationship with the cocatalyst activator.
The catalysts may be used to polymerize ethylenically and/or acetylenically unsaturated monomers having from 2 to 20 carbon atoms either alone or in combination. Preferred monomers include the C 2-10 α-olefins especially ethylene, propylene, isobutylene, 1-butene, 1-hexene, 4-methyl-1-pentene, and 1-octene and mixtures thereof. Other preferred monomers include vinylcyclohexene, vinylcyclohexane, styrene, C 1-4 alkyl substituted styrene, tetrafluoroethylene, vinylbenzocyclobutane, ethylidenenorbornene and 1,4-hexadiene.
In general, the polymerization may be accomplished at conditions well known in the prior art for Ziegler-Natta or Kaminsky-Sinn type polymerization reactions, that is, temperatures from 0-250° C. and pressures from atmospheric to 3000 atmospheres. Suspension, solution, slurry, gas phase or high pressure, whether employed in batch or continuous form or under other process conditions, may be employed if desired. For example, the use of condensation in a gas phase polymerization is a especially desirable mode of operation for use of the present catalysts. Examples of such well known polymerization processes are depicted in WO 88/02009, U.S. Pat. Nos. 5,084,534, 5,405,922, 4,588,790, 5,032,652, 4,543,399, 4,564,647, 4,522,987, and elsewhere, which teachings disclose conditions that can be employed with the polymerization catalysts of the present invention. A support, especially silica, alumina, or a polymer (especially polytetrafluoroethylene or a polyolefin) may be employed, and desirably is employed when the catalysts are used in a gas phase polymerization process with or without condensation. Methods for the preparation of supported catalysts are disclosed in numerous references, examples of which are U.S. Pat. Nos. 4,808,561, 4,912,075, 5,008,228, 4,914,253, and 5,086,025 and are suitable for the preparation of supported catalysts of the present invention.
In most polymerization reactions the molar ratio of catalyst:polymerizable compounds employed is from 10 −12 :1 to 10 −1 :1, more preferably from 10 −12 :1 to 10 −5 :1.
Suitable solvents for solution, suspension, slurry or high pressure polymerization processes are noncoordinating, inert liquids. Examples include straight and branched-chain hydrocarbons such as isobutane, butane, pentane, hexane, heptane, octane, and mixtures thereof; cyclic and alicyclic hydrocarbons such as cyclohexane, cycloheptane, methylcyclohexane, methylcycloheptane, and mixtures thereof; perfluorinated hydrocarbons such as perfluorinated C 4-10 alkanes, and aromatic and alkyl-substituted aromatic compounds such as benzene, toluene, and xylene. Suitable solvents also include liquid olefins which may act as monomers or comonomers including ethylene, propylene, butadiene, cyclopentene, 1-hexene, 3-methyl-1-pentene, 4-methyl-1-pentene, 1,4-hexadiene, 1-octene, 1-decene, styrene, divinylbenzene, allylbenzene, and vinyltoluene (including all isomers alone or in admixture). Mixtures of the foregoing are also suitable.
Having described the invention the following examples are provided as further illustration thereof and are not to be construed as limiting. Unless stated to the contrary all parts and percentages are expressed on a weight basis. The invention herein disclosed may be performed in the absence of any reagent not specifically described. The term “overnight”, if used, refers to a time of approximately 16-18 hours, “room temperature”, if used, refers to a temperature of about 20-25° C., and “mixed alkanes” or “alkanes” refers to a mixture of mostly C 6 -C 12 isoalkanes available commercially under the trademark Isopar E™ from Exxon Chemicals Inc.
All manipulation of air sensitive materials was performed in an argon filled, vacuum atmospheres, glove box or on a high vacuum line using standard Shlenk techniques. Solvents were purified by passage through columns packed with activated alumina (Kaiser A-2) and supported copper (Engelhard, Cu-0224 S). Anhydrous C 6 D 6 and CH 2 Cl 2 were purchased from Aldrich and used as received. NMR spectra were recorded on a Varian XL-300 instrument ( 1 H, 300 MHz; 13 C{ 1 H}, 75 MHz). 1 H and 13 C{ 1 H} NMR spectra are reported relative to tetramethylsilane and are referenced to the residual solvent peak.
MeLi, bis(dichloromethylsilyl)ethane, triethylamine and tert-butylamine were purchased from Aldrich and used as received. Bis(dichloromethylsilyl)hexane (United Chemical Technologies), n-butyllithium (ACROS) and 2-methyl-4-phenylindene (Boulder Scientific) were used as received. 1-N-pyrrolidineindene was prepared via the route of Noland, et al., JOC, 1981, 46, (1940) It's lithium salt, (1-(1-pyrrolidinyl)-1H-indenyl)lithium, was prepared by reaction with butyllithium in hexanes and recovered by filtration.
EXAMPLE 1
(μ-((1,1′-(1,6-hexanediyl)bis(N-(1,1-dimethylethyl)-1-methyl-1-((1,2,3,3a,7a-η)-3-(1-pyrrolidinyl)-1H-inden-1-yl)silanaminato-κN)(4-))))tetrachlorodititanium
A 1,1′-(1,6-hexanediyl)bis(1-chloro-N-(1,1-dimethylethyl)-1-methyl)-silanamine
To a −10° C. solution of 1,6-bis(chloromethylsilyl)hexane (25.00 g, 80.1 mmol) and triethylamine (24.6 mL, 0.176 mole) in 250 mL of dichloromethane was added dropwise over 1 hour a solution of tert-butylamine (16.8 mL, 0.160 mole) in 100 mL of dichloromethane. The suspension was allowed to warm to room temperature. After stirring overnight, most to the volatiles were removed in vacuo. The product was extracted into 175 mL of hexanes, filtered and the hexanes removed in vacuo to leave 29.5 g (96 percent yield) of 1,1′-(1,6-hexanediyl)bis(1-chloro-N-(1,1-dimethylethyl)-1-methyl)silanamine as a pale-pink viscous liquid.
1 H NMR (C 6 D 6 ): 1.35 (m, 4H), 1.24 (m, 4H), 1.13 (s, 18H), 1.03 (br s, 2H), 0.75 (m, 4H), 0.33 (s, 6H). 13 C{ 1 H} (C 6 D 6 ): 50.35, 33.42, 32.95, 23.74, 20.34, 3.12.
B) 1,1′-(1,6-hexanediyl)bis(N-(1,1-dimethylethyl)-1-methyl-1-(3-(1-pyrrolidinyl)-1H-inden-1-yl)-silanamine
To a −30° C. solution of 1,6-bis(N-(tert-butyl)-1-chloro-1-methylsilanamine)hexane (1.50 g, 3.89 mmol) in 20 mL of THF was added a precooled (−30° C.) solution of (1-(1-pyrrolidinyl)-1H-indenyl)lithium (1.49 g, 7.78 mmol) in 10 mL of THF. The reaction was allowed to warm to room temperature as it gradually darkened and changed to a deep-red/purple solution with slight green flourescence. After 16 hours, the volatiles were removed in vacuo and 50 mL of hexanes added. The suspension was filtered and hexanes removed from the filtrate in vacuo to leave 2.5 g (92 percent yield) of 1,1′-(1,6-hexanediyl)bis(N-(1,1-dimethylethyl)-1-methyl-1-(3-(1-pyrrolidinyl)-1H-inden-1-yl)-silanamine as a red/purple oil.
1 H NMR (C 6 D 6 ): 7.71 (m, 4H), 7.27 (m, 4H), 5.47/5.43 (2 s, 2H, isomers), 3.51 (s, 2H), 3.29 (br s, 8H), 1.64 (sh m, 8H), 1.30 (m, 8H), 1.11 (set of several sharp peaks, 18H), 0.616 (br s, 2H), 0.50 (s, 4H), 0.20/0.04 (2 singlets, 6H, isomers). 13 C{ 1 H} (C 6 D 6 ): 149.21, 146.99, 141.66, 124.85, 124.63, 123.95, 123.82, 120.95, 105.11, 50.86, 49.54, 43.20 (m), 34.05, 25.42, 24.51, 17.25/16.19 (isomers), −0.71/−1.88 (isomers).
C) 1,1′-(1,6-hexanediyl)bis(N-(1,1-dimethylethyl)-1-methyl-i-(3-(1-pyrrolidinyl)-1H-inden-1-yl)t 2 , (deloc-1,2,3,3a,7a:1′, 2′,3′,3′,3′a,7′a)-silanamine, dilithium, dilithium salt
To a solution of 1,6-bis((N-(tert-butyl)-1-methyl-1-(3-(1-pyrrolidinyl)-1H-inden-1-yl)silanamine))hexane (2.45 g, 3.6 mmole) in 50 mL of toluene was added over 15 minutes a solution of n-butyl lithium in hexanes (1.60 M, 9.42 mL, 15.0 mmol). Over the period of addition, the original red solution turns orange followed by formation of a yellow precipitate. After stirring for 14 hours, the yellow precipitate was collected by filtration and washed twice with 10 mL of toluene and then twice with 10 mL of hexanes. The dark yellow solid was dried in vacuo for 8 hours to leave 2.6 g (quantitive yield) of the desired product.
D) (μ-((1,1′-(1,6-hexanediyl)bis(N-(1,1-dimethylethyl)-1-methyl-1-((1,2,3,3a,7a-η)-3-(1-pyrrolidinyl)-1H-inden-1-yl)silanaminato-κN)(4-))))tetrachlorodititanium
To a precooled (−30° C.) suspension of TiCl 3 (THF) 3 (1.42 g, 3.82 mmol) in 30 mL of THF was added a precooled (−30° C.) 30 mL THF solution of 1,6-bis((N-(tert-butyl)-1-methyl-1-(3-(1-pyrrolidinyl)-1H-inden-1-yl)silanamine))hexane, tetralithium salt (1.35 g, 1.91 mmol). Immediately the color changed to very dark blue/green. After stirring at room temperature for 45 minutes, PbCl 2 (0.8 g, 2.879 mmol) was added. The color gradually changed to dark blue/purple as lead balls formed. After 1 hour, the volatiles were removed in vacuo and the product extracted into 25 mL of toluene, filtered and the volatiles removed in vacuo. The dark blue/purple residue was dried in vacuo for 4 hours and then triturated in hexanes (30 mL). The hexanes were removed in vacuo and 30 mL of hexanes was added followed by trituration again. The resulting purple/black suspension was filtered, the solid washed with hexanes and dried in vacuo overnight to leave 1.42 g (83 percent yield) of the desired product as a purple/black solid.
1 H NMR (C 6 D 6 ): 7.62 (br s, 4H), 7.08 (br s, 4H), 5.67 (m, 2H), 3.58 (br s, 4H), 3.22 (brs, 4H), 1.49 (brs, 36H), 1.8-0.50 (m, 23H), 13 C{ 1 H} (C 6 D 6 ): 149.7 (m), 136.5, 135.5, 129.04, 128.9, 127.2, 126.4, 125.3, 106.77/106.29 (isomers), 92.3, 60.9, 50.6, 25.7, 24.3/24.0 (isomers), 19.7, 18.19, 14.34, 1.87/−0.54 (isomers).
EXAMPLE 2
(μ-((1,1′-(1,6-hexanediyl)bis(N-(1,1-dimethylethyl)-1-methyl-1-((1,2,3,3a,7a-η)-3-(1-pyrrolidinyl)-1H-inden-1-yl)silanaminato-κN)(4-))))tetramethyldititanium
To a suspension of (μ-((1,1′-(1,6-hexanediyl)bis(N-(1,1-dimethylethyl)-1-methyl-1-((1,2,3,3a,7a-η)-3-(1-pyrrolidinyl)-1H-inden-1-yl)silanaminato-κN)(4-))))tetrachlorodititanium (0.189 g, 0.21 mmol) in 10 mL of diethyl ether was added a solution of MeLi (1.4 M/Et 2 O, 0.59 mL, 0.82 mmol). Instantly the solution turned dark red. After stirring at room temperature for 1 hour, the volatiles were removed in vacuo and the product extracted into 20 mL of hexanes. The suspension was filtered and the brown filter cake washed until no appreciable red color appeared in the washing. The volatiles were removed from the red filtrate and the residue dried in vacuo for 1 hour. The residue was extracted into hexanes (15 mL) and filtered to remove trace amounts of fine particulates. The hexanes were removed from the filtrate in vacuo and the resulting red ‘flaky’ solid dried in vacuo overnight to leave 0.130 g (75 percent yield) of red solid.
1 H NMR (C 6 D 6 ): 7.73 (m, 2H), 7.50 (m, 2H), 7.04 (m, 2H), 6.89 (m, 2H), 5.42 (m, 2H), 3.43 (m, 4H), 3.25 (m, 4H), 1.53 (sh m, 36H), 1.8-0.50 (m, 20H), 0.09 (br s, 6H). 13 C{ 1 H} (C 6 D 6 ): 144.16 (m), 133.99, 133.31, 125.60, 125.13, 124.73, 123.90, 104.642, 104.02, 83.90, 57.78, 54.34, 54.13, 50.63, 48.86, 34.91, 33.99, 33.86, 26.05, 24.73, 24.38, 20.84,19.20, 2.86, 0.39.
EXAMPLE 3
(μ-((1,1′-(1,2-ethanediyl)bis(N-(1,1-dimethylethyl)-1-methyl-1-((1,2,3,3a,7a-η)-3-(1pyrrolidinyl)-1H-inden-1-yl)silanaminato-κN)(4-))))tetrachlorodititanium
A) 1,1′-(1,2-ethanediyl)bis(1-chloro-N-(1,1-dimethylethyl)-1-methyl)silanamine
To a −10° C. solution of and 1,6-bis(dichloromethylsilyl)ethane (5.00 g, 19.5 mmol) and triethylamine (6.0 mL, 43 mmol) in 50 mL of CH 2 Cl 2 was added dropwise over 1 hour a solution of tert-butylamine (4.1 mL, 39.0 mmol) in 20 mL of CH 2 Cl 2 . The obtained white suspension was allowed to warm to room temperature. After stirring for 16 hours, most of the solvent was removed in vacuo and 75 mL of hexanes added. The resulting suspension was filtered and the volatiles removed from the filtrate in vacuo to leave 1,6-bis(N-(tert-butyl)-1-chloro-1-methylsilanamine)ethane (5.7 g, 97 percent yield) as a pale pink oily solid.
1 H NMR (C 6 D 6 ): 1.12 (s, 18H), 1.03 (br s, 2H), 0.91 (m, 4H), 0.33/0.32. (two s, 6H, isomers). 13 C{ 1 H} (C 6 D 6 ): 50.36, 33.32, 32.95, 12.65/12. (two peaks/isomers), 2.39/2.13 (two peaks/isomers).
B) 1,1′-(1,2-ethanediyl)bis(N-(1,1-dimethylethyl)-1-methyl-1-(3-(1-pyrrolidinyl)-1H-inden-1-yl)-silanamine
To a −30° C. solution of (1-(1-pyrrolidinyl)-1H-indenyl)lithium (1.705 g, 8.92 mmol) in 10 mL of THF was added a −30° C. solution of 1,6-bis(N-(tert-butyl)-1-chloro-1-methylsilanamine)ethane (1.47 g, 4.46 mmol) in 5 mL of THF. The reaction was allowed to warm to room temperature as it gradually darkened and changed to a deep-red/purple solution with slight green fluorescence. After 16 hrs at room temperature, the volatiles were removed in vacuo and then 50 mL of hexanes was added. The suspension was filtered and the hexanes removed from the filtrate in vacuo to leave 1,6-bis((N-(tert-butyl)-1-methyl-1-(3-(1-pyrrolidinyl)-1H-inden-1-yl)silanamine)ethane (2.7 g, 97% yield) as a red/purple oil.
1 H NMR (C 6 D 6 ): 7.75-7.55 (m, 4H), 7.40-7.15 (m, 4H), 5.42 (m, 2H), 3.505 (m, 2H), 3.29 (br s, 8H), 1.65 (br s, 8H), 1.09 (set of several sharp peaks, 18H), 0.88 (m, 2H), 0.54 (m, 4H), 0.45-0.00 (m, 6H). 13 C{ 1 H} (C 6 D 6 ): 149.07, 147.03, 141.59, 124.58, 124.39, 123.98, 123.78, 120.92, 105.22, 50.86, 49.49, 42.80 (m), 34.13, 25.43, 11.0-8.0 (m), 0.0-(−3.0) (m).
C) 1,1′-(1,2-ethanediyl)bis(N-(1,1-dimethylethyl)-1-methyl-1-(3-(1-pyrrolidinyl)-1H-inden-1-yl) −2 , (deloc-1,2,3,3a,7a:1′, 2 ′, 3 ′, 3 ′a,7′a)-silanamine, dilithium, dilithium salt
To a stirred solution of 1,6-bis((N-(tert-butyl)-1-methyl-1-(3-(1-pyrrolidinyl)-1H-inden-1-yl)silanamine))ethane (2.7 g, 4.31 mmol) in 50 mL of toluene was added n-BuLi (11.3 ml, 1.6 M, 18.1 mmol) over fifteen minutes. The original red solution slowly turned to a orange-yellow suspension over one hour. After 16 hours, the yellow/orange suspension was filtered and washed with toluene until the washings became colorless (4×5 mL washes). The sample was then washed 3 times with 20 mL of hexanes and dried in vacuo for 5 hours to leave 2.60 g (93 percent yield) of 1,6-bis((N-(tert-butyl)-1-methyl-1-(3-(1-pyrrolidinyl)-1H-inden-1-yl)silanamine))ethane, tetralithium salt as a fine yellow powder.
D) (μ-((1,1′-(1,2-ethanediyl)bis(N-(1,1-dimethylethyl)-1-methyl-1-((1,2,3,3a,7a-η)-3-(1-pyrrolidinyl)-1H-inden-1-yl)silanaminato-κN)(4-))))tetrachlorodititanium
To a precooled (−30° C.) suspension of TiCl 3 (THF) 3 (1.27 g, 3.44 mmol) in 20 mL of THF was added a precooled (−30° C.) 20 mL THF solution of 1,6-bis((N-(tert-butyl)-1-methyl-1-(3-(1-pyrrolidinyl)-1H-inden-1-yl)silanamine))ethane, tetralithium salt (1.12 g, 1.72 mmol). Immediately the color changed to very dark blue/green. After stirring at room temperature for 1 hour, PbCl 2 (0.67 g, 2.4 mmol)was added. The color gradually changed to dark blue/purple as lead particles formed. After 1 hour, the volatiles were removed in vacuo and the residue dried in vacuo for 1 hour. The product was extracted into 60 mL of toluene, filtered and the volatiles removed in vacuo. After drying the dark residue in vacuo for an hour, hexanes (20 mL) was added and the dark solid triturated. The volatiles were removed in vacuo, 20 mL of hexanes were added and the solid triturated again. The resulting purple/black suspension was filtered and the solid washed twice with 3 mL of hexanes and dried in vacuo overnight to leave 1.35 g (91 percent yield) of the desired product as a dark purple solid.
1 H NMR (C 6 D 6 ): 7.80-7.55 (m, 4H), 7.30-6.70 (m, 4H), 5.75 (m, 2H), 3.75-3.00 (m, 4H), 1.45 (br s, 36H), 1.90-0.50 (m, 15H). 13 C{ 1 H} (C 6 D 6 ): 149.9 (m), 136.4, 135.5, 129.5, 129.3, 129.1, 127.4, 126.6, 126.4, 126.1, 106.1 (m), 92.4, 61.1, 50.7, 33.3, 25.9, 15-9 (m), 0.92/0.81/−1.19 (isomers).
EXAMPLE 4
(μ-((1,1′-(1,2-ethanediyl)bis(N-(1,1-dimethylethyl)-1-methyl-1-((1,2,3,3a,7a-η)-3-(1-pyrrolidinyl)-1H-inden-1-yl)silanaminato-κN)(4-))))tetramethyldititanium
To a suspension of (μ-((1,1′-(1,2-ethanediyl)bis(N-(1,1-dimethylethyl)-1-methyl-1-((1,2,3,3a,7a-η)-3-(1-pyrrolidinyl)-1H-inden-1-yl)silanaminato-κN)(4-))))tetrachlorodititanium (0.430 g, 0.50 mmol) in 25 mL of diethyl ether was added a solution of MeLi (1.4 M/Et 2 O, 1.43 mL, 2.00 mmol). Instantly the solution turned dark red. After stirring at room temperature for 1 hour, the volatiles were removed in vacuo and the sample dried in vacuo for 1 hour. The product was extracted into 50 mL of hexanes, the suspension filtered and the brown filter cake washed until no appreciable red color appeared in the washing. The volatiles were removed from the red filtrate and the residue dried in vacuo for 2 hours. The residue was extracted again into hexanes (15 mL) and filtered to remove trace amounts of an insoluble brown residue. The hexanes were removed from the filtrate in vacuo and the resulting red solid dried in vacuo overnight to leave 0.280 g (67 percent yield) of red solid.
1 H NMR (C 6 D 6 ): 7.85-7.45 (m, 4H), 7.10-6.65 (m, 4H), 5.56 (m, 2H), 3.46 (br s, 4H), 3.28 (br m, 4H), 1.55 (sh m, 36H), 1.8-0.50 (m, 12H), 0.09 (m, 6H). 13 C{ 1 H} (C 6 D 6 ): 144.2 (m), 134.1, 133.8, 126.0-124.0 (m), 104.6 (m), 83.85 (m), 57.89 (m), 54.5 (m), 50.52 (m), 51.0-49.0 (m), 34.99, 26.09, 15.0-10.0 (m), 2.0 (m), −0.40 (m).
EXAMPLE 5
(μ-((1,1′-(1,6-hexanediyl)bis(N-(1,1-dimethylethyl)-1-methyl-1-((1,2,3,4,5-η)-2,3,4,5-tetramethyl-2,4-cyclopentadien-1-yl)silanaminato-κN)(4-))))tetrakis(phenylmethyl)di-titanium
A) 1,6-hexanediylbis(chloromethyl(2,3,4,5-tetramethyl-2,4-cyclopentadien-1-yl)silane
To a −10° C. solution of 1,6-bis(dichloromethylsilyl)hexane in 50 mL of THF was added dropwise over 1 hour a 30 mL THF solution of (2,3,4,5-tetramethycyclopentadienyl)magnesium-bromide.(THF) x (1.75 g, 5.49 mmol, 319 g/mol effective MW). The nearly colorless reaction was allowed to slowly warm to room temperature. After stirring overnight, the volatiles were removed in vacuo. The product was extracted into 75 mL of hexanes, filtered and the filter cake washed several times with hexanes. The volatiles were removed from the filtrate in vacuo to leave 1.25 g (94 percent yield) of 1,6-bis(1-(1,2,3,4-tetramethylcyclopentadienyl)-1-chloro-1-methylsilyl)hexane as a off-white waxy solid.
1 H NMR (C 6 D 6 ): 2.99 (br s, 2H), 1.98 (overlapping s, 12H), 1.754 (s, 12H), 1.50-1.10 (m, 8H), 0.80-0.50 (m, 4H), 0.19(s,6H). 13 C{ 1 H} (C 6 D 6 ):137.87, 131.65, 55.98, 33.12, 23.64, 16.74,14.67, 11.51, −0.64.
B) 1,1′-(1,6-hexanediyl)bis(N-(1,1-dimethylethyl)-1-methyl-1-(2,3,4,5-tetramethyl-2,4-cyclopentadien-1-yl)silanamine
To a solution of triethylamine (0.9 mL, 6.46 mmol) and 1,6-bis(1-(1,2,3,4-tetramethylcyclopentadienyl)-1-chloro-1-methylsilyl)hexane (1.25 g, 2.58 mmol) in 30 mL of CH 2 Cl 2 was added tert-butylamine (0.6 mL, 5.69 mmol) all at once. The solution became cloudy as white precipitate formed. After stirring at room temperature for 2 hours, the volatiles were removed in vacuo and hexanes were added (30 mL). The hexanes extract was filtered and the filter cake washed twice with hexanes. The volatiles were removed from the filtrate in vacuo to leave 1.4 g (97percent yield) of 1,6-bis(N-(tert-butyl)-1-(1,2,3,4-tetramethyl-cyclopentadienyl)-1-methylsilanamine)hexane as a pale-yellow, viscous oil.
1 H NMR (C 6 D 6 ): 2.89 (br s, 2H), 2.15-1.70 (m, 265H), 1.41 (br s, 8H), 1.12 (s, 18H), 0.58/0.40 (m, 4H), 0.24 (s, 6H). 13 C{ 1 H} (C 6 D 6 ): 135.50, 133.47, 133.13, 56.37, 49.49, 34.03, 33.88, 24.61, 23.93, 17.12,15.28/15.18, 11.61, 0.50.
C) (μ-((1,1′-(1,6-hexanediyl)bis(N-(1,1-dimethylethyl)-1-methyl-1-((1,2,3,4,5-η)-2,3,4,5-tetramethyl-2,4-cyclopentadien-1-yl)silanaminato-κN)(4-))))tetrakis(phenylmethyl)di-titanium
A Schlenk flask was charged with a hexanes solution (80 mL) of tetra(benzyl)titanium (1.433 g, 3.47 mmol) and 1,6-bis(N-(tert-butyl)-1-(tetramethylcyclopentadienyl)-1-methylsilanamine)hexane (0.88 mg, 1.58 mmol). The reaction was heated to 60° C. for 22 hours. The reaction was taken into the glovebox and heated to reflux for 4 hours. The volatiles were removed in vacuo, the residue extracted with hexanes (75 mL), filtered and the volatiles removed in vacuo. The residue was again extracted into hexanes (50 mL), filtered, and the filtrate concentrated to about 10 mL. After cooling the solution at −30° C. overnight, the mother liquor was filtered and the oily dark solid washed twice with 5 mL of hexanes. The volatiles were removed from the filtrate in vacuo to leave 1.2 g (75 percent yield) of the desired product as an oily gold-brown solid.
1 H NMR (C 6 D 6 ): 7.13 (m, 8H), 6.85 (m, 12H), 3.0-0.0 (several overlapping multiplets with distinct peaks at around 1.75, 1.45 and 0.5 ppm). 13 C{ 1 H} (C 6 D 6 ): 150.35, 134.92, 134.32, 131.85 (m), 128.35, 127.15 (br s), 122.92, 122.34, 83.10, 82.06, 84-80 (underlying mult.), 60.18, 38.5, 36.75, 34.49, 33.92, 16.0-11.0 (m), 3.45.
EXAMPLE 6
(μ-((1,1′-(1,2-ethanediyl)bis(N-(1,1-dimethylethyl)-1-methyl-1-((1,2,3,4,5-η)-2,3,4,5-tetramethyl-2,4-cyclopentadien-1-yl)silanaminato-κN)(4-))))tetrakis(phenylmethyl)di-titanium
A) 1,2-ethanediylbis(chloromethyl(2,3,4,5-tetramethyl-2,4-cyclopentadien-1-yl)silane
To a 0° C. solution of 1,6-bis(dichloromethylsilyl)ethane (5.73 9, 22.4 mmol) in 100 mL of THF was added dropwise over 1.5 hour a 300 mL THF solution of (2,3,4,5-tetramethylcyclopentadienyl)magnesiumchlorides(THF)) (11.06 g, 44.8 mmol, 247 g/mol effective MW). The reaction was allowed to slowly warm to room temperature overnight. After 17 hours, the volatiles were removed in vacuo and the resulting off white solid dried in vacuo for an additional hour. To the solid was added 150 mL of hexanes and the suspension vigorously stirred for 10 minutes. The suspension was filtered and the volatiles removed in vacuo from the pale yellow filtrate. After thorough drying, 9.41 g (98 percent yield) of the desired product was obtained as an off-white solid.
1 H NMR (C 6 D 6 ): 2.97 (br s, 2H), 1.99 (s, 6H), 1.92 (s, 6H), 1.74 (s, 12H), 0.9-0.5 (m, 4H), 0.15 (s, 6H). 13 C{ 1 H} (C 6 D 6 ): 138.02, 131.58 (br), 55.67, 14.67, 11.52, 9.13,-1.18.
B) 1,1′-(1,6-ethanediyl)bis(N-(1,1-dimethylethyl)-1-methyl-1-(2,3,4,5-tetramethyl-2,4-cyclopentadien-1-yl)silanamine
To a solution of triethylamine (7.7 mL, 55 mmol) and 1,2-ethanediylbis(chloromethyl-(2,3,4,5-tetramethyl-2,4-cyclopentadien-1-yl)-silane (9.4 g, 21.98 mmol) in 80 mL of CH 2 Cl 2 was added tert-butylamine (5.1 mL, 48 mmol) all at once. A white suspension quickly formed. After stirring for three hours, the volatiles were removed in vacuo and the product into hexanes (120 mL). The suspension was filtered and washed twice with 10 mL of hexanes. The hexanes were remove in vacuo to leave 10.33 g (100 percent yield) of 1,6-bis(N-(tert-butyl)-1-(1,2,3,4-tetramethyl-cyclopentadienyl)-1-methylsilanamine)ethane as a pale-yellow, viscous oil.
1 H NMR (C 6 D 6 ): 2.90/2.82 (two s, 2H, isomers), 2.10-1.70 (m, 26H), 1.13/1.10 (two s, 18H, isomers), 0.46 (m, 4H), 0.30-0.15 (m, 6H). 13 C{ 1 H} (C 6 D 6 ): 135.4 (m), 30 133.67, 133.22, 56.14 (m), 49.37, 33.95, 15.05 (m), 11.46, 9.01 (m), −0.20 (m).
C) (μ-((1,1′-(1,2-ethanediyl)bis(N-(1,1-dimethylethyl)-1-methyl-1-((1,2,3,4,5-η)-2,3,4,5-tetramethyl-2,4-cyclopentadien-1-yl)silanaminato-κN)(4-))))tetrakis(phenylmethyl)dititanium
A Schlenk flask was charged with a hexanes solution (90 mL) of tetra(benzyl)titanium (1.97 g, 4.78 mmol) and 1,6-bis(N-(tert-butyl)-1-(Me 4 Cp)-1-methylsilanamine)ethane (1.022 g, 2.17 mmol). The reaction was heated to 60° C. for 19 hours and the resulting dark yellow/brown solution was then heated to reflux for an additional four hours. The volatiles were removed in vacuo and the product extracted into hexanes (100 mL). The suspension was filtered to remove some black solid and the volatiles were removed from the filtrate. The residue was dried in vacuo for one hour and then extracted with hexanes again (70 mL). The suspension was filtered and the volatiles removed from the filtrate. The residue was again extracted with hexanes (50 mL), filtered and the filtrate concentrated to about 20 mL. The dark solution was cooled at −30° C. overnight. The solution was decanted away from the black oily residue and the residue washed twice with 5 mL of hexanes. The hexanes filtrate was concentrated to 5 mL and cooled at −30° C. overnight. The solution was filtered and the small amount of black insoluble residue was washed with hexanes. The volatiles were removed from the hexanes filtrate in vacuo and the solid dried in vacuo for 5 hours to leave 1.25 g (62 percent yield) of desired complex as a dark gold-brown solid.
1 H NMR (C 6 D 6 ): 7.13 (m, 8H), 6.85 (m, 12H), 3.0-0.0 (several overlapping multiplets with distinct peaks at around 1.75, 1.45 and 0.5 ppm). 13 C{ 1 H} (C 6 D 6 ): 150.35, 134.92, 134.32, 131.85 (m), 128.35, 127.15 (brs), 122.92, 122.34, 83.10, 82.06, 84-80 (underlying multiplets), 60.18, 38.5, 36.75, 34.49, 33.92, 16.0-11.0 (m), 3.45.
EXAMPLE 7
bis(1,1′-(η 4 -1,3-butadiene-1,4-diyl)bis(benzene))(L-(1,6-hexanediylbis((methylsilylidyne)bis((1,2,3,3a,7a-η)-2-methyl-4-phenyl-1H-inden-1-ylidene))))dizirconium
A) Lithium 2-methyl-4-phenylindenide
To a solution of 2-methyl-4-phenylindene (10.03 g, 49.3 mmol) in 200 mL of hexanes was added dropwise over 10 minutes 32 mL of 1.6M n-BuLi. The resulting yellow suspension was stirred for 17 hours. The suspension was filtered and the solid washed twice with 5 mL of hexane. The light yellow solid was dried in vacuo for 2 hours to leave 9.21 g (89 percent yield) of lithium 2-methyl-4-phenylindenide. A second crop (0.61 g) was obtained by concentrating the filtrate to about 80 mL and filtering after 4 hours at room temperature. Overall yield was 9.82 g, 95 percent.
B) 1.6-hexanediylbis(methylbis(2-methyl-4-phenyl-1H-inden-1-yl)-silane
A solution of 1,6-bis(dichloromethylsilyl)hexane (1.78 g, 5.69 mmol) in 20 mL of toluene was added dropwise over 30 minutes to a solution of lithium 2-methyl-4-phenylindenide (5.00 g, 23.9 mmol) in 60 mL of THF. The cloudy orange solution was left to stir at room temperature for 20 hours and then quenched by slow addition of water (80 mL). Most of the THF was removed by rotary evaporation and the product extracted into diethyl ether (120 mL). The organic/aqueous layers were separated and the aqueous layer washed twice with 50 mL of diethyl ether. The organic extracts were combined, dried over MgSO 4 , filtered and most of the volatiles removed in vacuo. The reaction residue was dissolved in enough toluene to make about 25 mL of a viscous solution. The reaction mixture was subsequently chromatographed on silica (35 cm×5 cm column) initially eluting with hexanes followed by 4:1 hexanes:CH 2 Cl 2 to remove excess 2-methyl-4-phenylindene (Rf=0.62 (silica, 2:1 hexanes:dichloromethane). Further elution with 4:1 hexanes:CH 2 Cl 2 gave one fraction of the desired product 1,6-bis[methylsilyl-bis(2-methyl-4-phenyl-indenyl)hexane (Rf≅0.38 silica, 2:1 hexanes:dichloromethane) which was isolated by removal of volatiles in vacuo to leave 1.53 g (27%) of pale yellow solid. Further elution with 3:1 hexanes:CH 2 Cl 2 led to isolation of a second fraction which has a much broader elution bandwidth (Rf≅0.35-0.10). Removal of volatiles in vacuo from the sample gave 1.89 g (34 percent) of pale yellow solid. Overall yield was 3.42 g (61 percent).
1 H NMR (CDCl 3 ): 7.70-6.9 (m, 32H), 6.74 (m, 4H), 4.0-3.5 (m, 4H), 2.4-1.9 (m, 12H), 1.6-0.4 (m, 12H), 0.45-(−0.2) (m, 6H). 13 C{ 1 H} (CDCl 3 ): 158.2, 150.9, 148.2 (m), 145.9,143.1 (m), 141.6 (m), 140.55, 137.6, 134.31, 130-120 (several multiplets.), 77.1 (m), 48.9, 47.3 (m), 33.5, 24.1, 18.1 (m), 15.1 (m), 13.2 (m), 12.4 (m), −5.4 (m).
B) 1,6-hexanediylbis(methylbis(2-methyl-4-phenyl-1H-inden-1-yl)-silane, ion(4-), tetralithium
To a 20 mL toluene solution of 1,6-bis[methylsilyl-bis(2-methyl-4-phenyl-indenyl)hexane (1.01 g, 1.04 mmol) was added n-butyl lithium over 10 minutes (2.7 mL, 1.6 M in hexanes, 4.29 mmol). After 20-30 minutes, a yellow precipitate began to form. After stirring for 18 hours at room temperature, the yellow-orange suspension was filtered and washed twice with 6 mL of toluene then twice with 5 mL of hexane. The sample was dried in vacuo for 5 hours until the weight of sample stabilized to leave 0.91 g (89 percent yield) of tetralithium 1,6-bis[methylsilyl-bis(2-methyl-4-phenyl-indenylide)hexane as a yellow powder.
C) bis(1,1′-(n 4 -1,3-butadiene-1,4-diyl)bis(benzene))(μ-(1,6-hexanediylbis((methylsilylidyne)bis((1,2,3,3a,7-η)-2-methyl-4-phenyl-1H-inden-1-ylidene))))dizirconium
To a −30° C. suspension of tetralithium 1,6-bis[methylsilyl-bis(2-methyl-4-phenyl-indenylide)hexane (0.300 mg, 0.30 mmol) in 5 mL of toluene was added a −30° C. solution of bis(triethylphosphine)(1,4-diphenylbutadiene)zirconium dichloride (0.432 g, 0.60 mmol) in 10 mL of toluene. The reaction was allowed to slowly warm to room temperature as the dark purple/black solution turned red. After stirring overnight, the solution was filtered and the volatiles removed in vacuo. The reaction residue was dissolved in 40 mL of toluene and added dropwise to 60 mL of hexanes. An additional 50 mL of 3:2 hexanes:toluene solvent mixture was added and the resulting orange/brown precipitate filtered and washed extensively with hexanes (3×30 mL). The volatiles were removed from the dark red filtrate and the oily red solid triturated with 10 mL of hexanes and the volatiles removed in vacuo. The trituration was repeated once more with 10 mL of hexanes and the obtained solid was filtered and washed with 5 mL of hexanes. The deep red solid was dried in vacuo overnight to leave 0.306 g (65 percent) of the desired product.
1 H NMR (CDCl 3 ): 8.0-7.6 (m, 4H), 7.6-6.6 (m, 52H), 5.6 (br s, 4H), 3.4 (m, 4H), 2.1-0.5 (m, 30H). 13 C{ 1 H} (C 6 D 6 ): 158.2, 150.9, 148.2 (m), 145.9, 143.1 (m), 141.6 (m), 140.55, 137.6, 134.31, 130-120 (several multiplets.), 77.1 (m), 48.9, 47.3 (m), 33.5, 24.1, 18.1 (m), 15.1 (m), 13.2 (m), 12.4 (m), −5.4 (m).
Polymerization
A two liter reactor is charged with 750 g of Isopar E and 120 g of octene-1 comonomer. Hydrogen is added as a molecular weight control agent by differential pressure expansion from a 75 ml additional tank from 300 psig (2070 Kpa) to 275 psig (1890 Kpa). The reactor is heated to the polymerization temperature of 140° C. and saturated with ethylene at 500 psig (3450 Kpa). The appropriate amount of catalyst and cocatalyst (trispentafluorophenyl)borane as 0.005 M solutions in toluene (approximately 4 μmole complex based on metal content) were premixed in a glovebox to give a 1:1 molar ratio of catalyst and cocatalyst, and transferred to a catalyst addition tank and injected into the reactor. The polymerization conditions were maintained for 10 minutes with ethylene on demand. The resulting solution was removed from the reactor into a nitrogen purged collection vessel containing 100 ml of isopropyl alcohol and 20 ml of a 10 weight percent toluene solution of hindered phenol antioxidant (Irganox™ 1010 from Ciba Geigy Corporation) and phosphorus stabilizer (Irgafos 168). Polymers formed are dried in a programmed vacuum oven with a maximum temperature of 120° C. and a 20 hours heating cycle. Results are shown in Table 1.
TABLE 1
Run
complex
Efficiency 1
MI 2
density 3
Mw/Mn
1
Ex. 2
0.6
<0.1
0.911
294,000/106/000
2
Ex. 4
0.3
0.1
0.911
299,000/138,000
3
Ex. 6
0.4
1.7
0.900
108,000/42,300
4
Ex. 5
0.5
1.9
0.901
106,000/50,600
5
Ex. 7
0.8
9.0
0.892
69,900/28,700
6*
TTiD 4
0.7
12.1
0.904
61,900/28,200
7*
BZrD 5
1.8
10.7
0.886
67,300/29,300
*not an example of the invention
1 efficiency, g polymer/μg metal
2 melt index, dg/min, measured by micromelt indexer
3 (g/cm 3 )
4 1,2-ethanebis(2-methyl-4-phenylinden-1-yl)zirconium (II) 1,4-diphenyl-1-3- butadiene
5 (t-butylamido)dimethyl(tetramethylcyclopentadienyl)silanetitanium (II) 1,3-pentadiene | Group 3-6 or Lanthanide metal complexes possessing two metal centers joined by means of a divalent bridging group joining trivalent moieties comprising boron or a member of Group 14 of the Periodic Table of the Elements, and optionally also comprising nitrogen, phosphorus, sulfur or oxygen, in the complexes, catalysts derived therefrom by combining the same with strong Lewis acids, Bronsted acid salts, salts containing a cationic oxidizing agent or subjected to bulk electrolysis in the presence of compatible, inert non-coordinating anions and the use of such catalysts for polymerizing olefins, diolefins and/or acetylenically unsaturated monomers are disclosed. | 72,610 |
RELATED APPLICATIONS
[0001] This application claims priority from U.S. provisional patent application No. 60/519,227, which was invented by the same inventor, was filed on Nov. 12, 2003, and was entitled “Wheel Illumination Device”.
FIELD OF THE INVENTION
[0002] The invention relates generally to motor vehicle accessories. More particularly, it relates to lights and sound systems for motor vehicles. Even more particularly, it relates to systems for lighting motor vehicle wheels.
BACKGROUND OF THE INVENTION
[0003] Lighting systems for automobiles have been known ever since automobiles were first invented. The first lighting systems consisted of kerosene lamps with clear or colored lenses mounted at various places on the body of the automobile to provide notice to others that the automobile was approaching, and to illuminate the automobile's surroundings. A major drawback to this system was the need to continuously recharge the lamps by filling them with oil, and trim the wicks. Further, the lamps put out a limited amount of light. Even further, unless adjusted carefully, they sooted up their reflectors.
[0004] Later, gas lighting systems were provided including lamps with integral to settling gas generators often called “carbide lamps”. Carbide lamps provide an intense light that is particularly suited for illuminating the road around the automobile. While it solved the problem of wick replacement, light intensity, and wick trimming, it still required each lamp to be separately filled and cleaned regularly.
[0005] As the systems further developed, centralized gas systems were devised in which a large central gas generator provided gas to several lamps disposed about the periphery of the vehicle. This problem reduce the need for maintaining each one of several different lamps, replacing it with a single, central problem of filling, emptying, and cleaning the central gas generator. Carbide gas generators produce a noxious mix of corrosive chemicals and sludge that cannot be disposed of easily
[0006] By the 1910's, battery-powered electrical lighting systems have been developed to replace the centralized gas arrangements. In these battery-powered systems, a battery disposed in the central location provided electrical energy to several lights mounted on the body of the vehicle. Wires extending from the battery were coupled to light bulbs that, in turn, illuminated the road in the surroundings of the vehicle. This solved the problem of periodic lamp cleaning, but replaced it with the problems of battery charging and battery maintenance. The batteries needed to be periodically charged. To do this, they must be either removed from the vehicle and taken to a charging station or the charging equipment must be brought to the battery in the vehicle. Either way, the lights require regular, even daily, adjustments and maintenance.
[0007] Not long after this, generators were provided on automobiles to charge the batteries used for lighting. These generators operated whenever the vehicles were running, charging the batteries to maintain a supply of electricity. This battery/generator arrangement is the most common form of present-day automotive lighting. Light elements, which include incandescent light bulbs as well as LEDs, are fixed to the body of the vehicle at various locations. Wires are coupled to these lighting elements to provide them with power. The power is provided by an alternator driven by the engine, which in turn is coupled to a battery. The battery acts as a reservoir of the electrical energy when the engine is stopped.
[0008] In addition to the centralized vehicle lighting systems, certain peripheral systems have been devised to provide extra lighting. For example, the automotive aftermarket product industry offers portable lights that plug into cigarette lighter outlets (more recently called “power outlets” since cigarettes have fallen on disfavor). These aftermarket lights can be fixed to a stalk supported by the outlet, or they can be disposed at the end of a flexible power cord that is plugged into the outlet. With these arrangements, the operator supports the light with his hand at the end of the power cord, which permits him to manipulate it and will, either inside or outside the operator's compartment.
[0009] Lights have been fixed to the interior of automobiles to light up upon the occurrence of various events, such as the unlocking of an automobile by remote control or other manipulation of remote control buttons, the opening of the door, or the opening of the trunk (boot) or hood (bonnet). Of course, it has been common to turn automotive lights on and off with electrical switches virtually since they were first used in automobiles.
[0010] Other automotive lighting systems have been triggered by optical sensors to turn on whenever the automobile (or rather, the optical sensor) is in darkness. These sensor arrangements are used with running lights (taillights and headlights) to ensure that the operator never drives the vehicle in the dark. Running lights serve two purposes: to illuminate the road for the operator's benefit, and to indicate to drivers ahead of the lighted automobile on the road and drivers behind the lighted automobile on the road of the automobile's presence.
[0011] Novelty lighting systems are a more recent development. Novelty lighting systems can be understood generally as lighting systems intended to enhance the beauty are stylishness of the automobile, and are not intended as safety measures or basic operational features. Running lights and courtesy or interior lights are not novelty lights.
[0012] Running lights, which include taillights, headlights, turn signals, parking lights, and reverse lights, are intended to enhance the safe operation of the vehicle over the road by indicating the presence of the automobile and its intentions to other automobile operators on the road. They are not “novelty lights”, although they may have novelty aspects such as special colors.
[0013] Courtesy or interior lights, which include dome lights, side lights, dashboard lights, console lights, indicator lights, map lights, and instrument lights, are not intended for operators of other vehicles, but for the operators and passengers of the vehicle itself, to permit them to enter and exit the vehicle safely, and to operate the various controls within the vehicle with ease, comfort and speed. They also are not novelty lights.
[0014] Novelty lights fall in the class of lights that are not necessary or required for safe operation of the vehicle or for the operator and passenger's ease and comfort, but for the personal satisfaction of the operator. Indeed, novelty lights, if viewable from outside the car, may be specifically banned in certain jurisdictions as interfering with vehicle running lights. Add-on or aftermarket lights may only be permissible to the extent they imitate already-permissible running lights. For example, large, high output, beamed white lights can only be used on the front of automobiles, and only if they are pointed in the same direction as the automobiles and headlights. In this sense, these aftermarket lights are not “novelty” lights, but supplements to (or replacements for) headlights.
[0015] Novelty lights are not the only customizable feature of an automobile. Wheels and wheel trim have been another area of novelty customization. Automobile wheels were originally imitations of wagon wheels, having a wooden hub, with wooden spokes that extended outward to a wooden rim with metal binding. As time passed, the hub was replaced with a steel hub and the individual wooden spokes were replaced with metal spokes. By the 1920's, the entire wheel was made out of stamped or pressed metal.
[0016] Not long after this, the enthusiasm for customizing automobiles expanded to include customizing wheels. Hubcaps were devised that provided a shiny or sparkling appearance to what was otherwise plain painted metal. Hub caps originally covered just the hub of the wheel. As time passed, and wheels became solid pressed or stamped metal structures, hubcaps extended all the way across the wheel from one side of the rim to the other.
[0017] Until recently, hubcaps were fixed to the wheel itself. Either attached to the rim, or attached to the hub, they are fixed to the wheel and rotated at exactly the same speed as the wheel. These devices had no moving parts. They achieved their eye-catching effects merely by the many reflections of ambient light off their numerous faceted reflective surfaces. Recently, however, caps have been designed to sparkle even when the vehicle is stopped by mounting them on the wheel (or wheel hub) with bearings. In normal operation, as the automobile travels down the road, the hubcap is gradually accelerated to the rotational speed of the wheel. Although it is bearing mounted, and thus can spend relatively freely with respect to the wheel, the close coupling between the wheel and the hubcap causes air currents and a certain amount of mechanical drag to accelerate the hubcap. The particular advantage to this arrangement is what happens when the car is stopped. When the operator breaks the vehicle, the wheels slow down. The hubcaps, however, keep spinning even after the vehicle is stopped (for example at a stoplight). Only gradually do the frictional drag of the surrounding air and the slight residual drag of the bearing supporting the hubcap on the wheel cause the hubcap to slow down. During this deceleration, the hubcap (which typically has many bright reflective faceted surfaces), sparkles and appears to an outside observer viewing the automobile from the side as a multiplicity of bright twinkling lights.
[0018] This arrangement, however, is limited. First, the hubcap only sparkles and twinkles with light when it rotates. When it is stopped, it no longer attracts the eye of the observer. Second, the speed at which the light reflected from the hubcap twinkles and sparkles is uncontrolled. It is strictly a function of the speed at which the hubcap turns, which depends upon the maximum speed of the car before deceleration, the speed of deceleration, and the friction between the hubcap and the wheel. None of these can be controlled with any accuracy. Third, the hubcap only sparkles and twinkles with light when an external light source is shined upon it. Without street lights, lights from surrounding buildings, or lighted signage, the spinning hubcaps are virtually invisible.
[0019] What is needed, therefore, is an improved lighting system for automobile wheels. What is also needed is a wheel illuminating system. What is also needed is a means for lighting the wheels as they rotate. What is also needed is a means of providing the wheels with rotating lights. It is an object of this invention to provide such a system.
[0020] These and other objects of the invention will become dear upon reading the description and examining the drawings below in which like-numbered items in all the drawings and the description represent the same elements, features, devices, structures, processes, or methods in all the other drawings and description.
SUMMARY OF THE INVENTION
[0021] In accordance with a first aspect of the invention, a system for illuminating an automobile wheel assembly of an automobile is provided, the wheel assembly including a hub, a wheel, and a tire, the system including a mount configured to be fixed to the wheel assembly, a plurality of lights fixed to the mount, a control circuit coupled to the plurality of lights to regulate the flow of electricity to the plurality of lights, and a power source coupled to the control circuit to provide said control circuit with electrical power for the lights, wherein the power source includes an electrical energy generating element as well as an electrical energy storing element.
[0022] The control circuit may be a switch. The control circuit may be configured to automatically turn the plurality of lights on and off. The control circuit can be configured to store light patterns. The control circuit can be configured to change light patterns automatically. The control circuit can further comprise a remote-control receiver configured to receive remote-control signals. The control circuit can be responsive to remote-control signals indicative of a pattern of light illumination. The control circuit can be configured to change the colors of the lights. The control circuit can be configured to turn the lights on and off. The control circuit can be configured to change the rate at which the lights are turned on and off. The control circuit can be responsive to automatically turn off the lights. The control circuit can be configured to energize the lights when the wheel assembly is stationary. The control circuit can be configured to change the intensity of the plurality of lights in synchrony with an audio source. The audio source may be a sound system disposed in the automobile.
[0023] The electrical energy generating element may be a generator. The generator may have a generator rotor and a generator stator. The generator rotor may be coupled to the wheel assembly to rotate with the wheel assembly when the automobile is driven over the ground. The generator stator may remain stationary as the automobile is driven or rotate at varying rates as long as the rate of rotation is less than the rate of rotation of the generator. The generator may be coupled to the automobile wheel assembly to rotate and generate electricity when the automobile is driven. The generator may be coupled to the automobile wheel assembly to not rotate and not generate electricity when the automobile is stopped. The electrical energy generating element may include a solar panel for direct conversion of light to electrical energy.
[0024] The plurality of lights may include LEDs, incandescent lights, fluorescent lights, neon, electroluminescent panels, and ultraviolet lights. Each of the plurality of lights may have a color different from others of the plurality of lights. The lights may be mounted in light mounts, such as swivels, flexible goosenecks, tubes, or extension tubes.
[0025] The lights may be coupled to a housing and face outward. The housing may support the light mounts in which the lights are mounted. The lights may be pointed to the wheel assembly to reflect light off the wheel assembly toward an observer. The lights may be coupled to a wheel of the wheel assembly. The lights may be coupled to a hole formed in the wheel. The lights may be stuck to the wheel.
[0026] The mount may include a housing. The housing may enclose the lights. The housing may enclose the control circuit. The housing may enclose the power source. The housing may include a cap removably fixed to a cylindrical unit base or a unit base which corresponds to the configuration of the cap. The cap may be screwed to the unit base. The cap may be configured as a spinner. The spinner may have three points, or be a three-point star. The spinner may have four points or be a four-point star. The solar panel may be fixed to an outer surface of the housing.
[0027] The system for illuminating a wheel assembly may further include a remote control configured to communicate with the control circuit. The remote control may be a wireless remote control. The remote control may be configured to activate the lights. The remote control may be configured to control the lights.
[0028] The mount may include a lower section fixed to the wheel assembly to rotate with the wheel assembly; an upper section enclosing the control circuit and the power source; and a bearing disposed between the lower section and the upper section to permit relative rotation between the lower section and the upper section. The upper section may include a unit base; and a cover; wherein the unit base and the cover are coupled together to define an internal cavity configured to receive and support the control circuit and the power source. The plurality of lights may be coupled to holes formed in the unit base. The plurality of lights may be coupled to the unit base and are directed toward the wheel. The plurality of lights may be selected from the group consisting of LEDs, incandescent, electroluminescent panels, neon, fluorescent lights, and ultraviolet lights. The electrical energy generating element may include a generator, and further wherein said generator may be coupled to said lower section to be driven thereby. The generator may be coupled to and charges the electrical energy storing element.
[0029] In accordance with a second aspect of the invention, a system for illuminating an automobile wheel assembly of an automobile is provided, wherein the wheel assembly includes a wheel and a tire, the system including: a plurality of lights configured to be supported on the wheel, a control circuit configured to be supported on the wheel, wherein the circuit is coupled to the plurality of lights and regulates a flow of electricity to the plurality of lights; and a power source configured to be supported on the wheel, wherein the power source is coupled to the control circuit to provide said control circuit and said plurality of lights with electrical power.
[0030] The control circuit may include a receiver responsive to a wireless remote control. The receiver may control the operation of the plurality of lights in response to signals received from the wireless remote control. The control circuit may control the plurality of lights to emit light in a plurality of light patterns, and further wherein the control circuit is responsive to the remote control to change the light patterns. The plurality of lights may be capable of emitting light when the wheel is not rotating and when the wheel is rotating. The system may further include a mounting plate having a plurality of holes that are configured to engage lug nuts securing the wheel to the automobile, wherein the plurality of lights, control circuit, and power source are supported by the mounting plate. The system may further include an enclosure supported by the mounting plate, wherein the plurality of lights, control circuit, and power source are supported within the enclosure. The wheel assembly may further include a hubcap, and further wherein the plurality of lights, control circuit, and power source are configured to be supported by the hubcap. The system may further include a mounting plate configured to be fixed to the hubcap, wherein the plurality of lights, control circuit, and power source are configured to be supported by the mounting plate. The system may further include the wireless remote control, which is configured to communicate with the receiver to control electrical power sent to the plurality of lights. The control circuit and plurality of lights may be configured to emit at least one pattern of light, and further wherein said wireless remote control is configured to change said at least one pattern of light. The control circuit may be configured to change an intensity of the plurality of lights in response to an audio signal received by the receiver. The control circuit may be configured to change a rate at which the plurality of lights go on and off in response to signals received by the receiver.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1 is a perspective view of an automobile having a wheel assembly with a wheel illumination device in accordance with the present invention attached thereto.
[0032] FIG. 2 is an exploded view of the wheel illumination device of FIG. 1 .
[0033] FIG. 3 is an end view of the lower section of the wheel illumination device of FIG. 2 .
[0034] FIGS. 4-5 are opposing end views of the unit base of the upper section of the wheel illumination device of FIGS. 1-3 showing the electronics box, rechargeable batteries, and lights installed inside the unit base.
[0035] FIGS. 6-9 are perspective views of four alternative covers for the upper section of wheel illumination device of FIGS. 1-3 .
[0036] FIGS. 10-13 are perspective side views of alternative light mounts for the wheel illumination device of FIGS. 1-5 .
[0037] FIGS. 14-15 are cross-sectional side and end views of the unit base of the wheel illumination system with the electronics box, rechargeable batteries, lights, and wiring removed to better show a generator.
[0038] FIG. 16 is a partial cross sectional view of the wheel assembly and wheel illumination device of the foregoing figures, wherein the wheel illumination device is coupled directly to a hubcap.
[0039] FIG. 17 is a plan view of a universal attachment plate for coupling the base of the wheel illumination device to a wheel.
[0040] FIG. 18 is a partial cross sectional view of the wheel illumination device of the foregoing FIGURES coupled to the universal attachment plate of FIG. 17 , which is in turn coupled to lug nuts of the wheel assembly.
[0041] FIG. 19 is a partial cross sectional view of the wheel illumination device of the foregoing FIGURES, coupled to a hub cover, which is in turn coupled to the universal attachment plate of FIG. 17 , which is in turn coupled to lug nuts of the wheel assembly.
[0042] FIG. 20 is a schematic representation of the control circuit of the wheel illumination device, including the circuitry in the electronics box, the battery and the generator.
[0043] FIG. 21 is a schematic representation of an in-car remote control system configured to communicate with and program the control circuit of the wheel illumination device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0044] FIG. 1 is a perspective view of an automobile 98 having a wheel assembly 114 , the wheel assembly having a wheel illumination device 100 attached thereto. Wheel illumination device 100 includes a housing 102 further comprising a cylindrical unit base 104 that is enclosed with a cover 106 . Several fasteners 108 extend through holes in cover 106 and are threadedly engaged with matching or corresponding holes (not shown) in base 104 . Lights 110 extend through apertures in the back of the wheel illumination device 100 , extending around the edges of the wheel illumination device where they are directed toward the wheel itself. Lights 110 are controlled by control circuitry (not shown) inside housing or enclosure 102 . A solar panel 112 is fixed to cover 106 to receive solar radiation and power the lights. Other power sources, discussed below, may also be used in place off, or in addition to solar panel 112 .
[0045] Housing 102 is fixed to universal mounting plate 300 , which is, in turn, fixed to lug nuts on the wheel. This mounting arrangement is shown in more detail in FIG. 18 .
[0046] Wheel assembly 114 includes a wheel 116 and a tire 118 mounted thereon. Wheel assembly 114 also includes a wheel hub (see e.g. the wheel of FIG. 19 ).
[0047] The wheel 116 of the automobile 98 is a front wheel that is steerable with respect to the rest of automobile 98 . Although wheel 116 is illustrated as a front wheel, it may also be a rear wheel. Automobile 98 has a wheel illumination device 100 fixed to each of the four wheels.
[0048] In FIG. 1 , the additional unused holes and slots in plate 300 have been removed for ease of illustration. It should be understood, however, that the plate 300 in FIG. 1 is the same plate 300 shown in FIGS. 17, 18 , and 19 .
[0049] FIG. 2 is an exploded view of the wheel illumination device 100 of FIG. 1 with lights 110 and fasteners 108 removed. The wheel illumination device includes a lower section 200 and an upper section 202 . Lower section 200 includes a base 204 and a shaft 206 . Upper section 202 comprises housing 102 , which includes a unit base 104 that is enclosed by a cap or cover 106 . Upper section 202 supports lights 110 , and electronics box 214 , and rechargeable batteries 216 . A solar panel 112 is affixed to the outside of cap or cover 106 .
[0050] Lower section 200 is provided to couple the remainder of the illumination device to the wheel assembly 114 . It has a base 204 for attaching the illumination device 100 to the wheel assembly 114 from which shaft 206 extends.
[0051] Referring now to FIGS. 2-3 , base 204 is preferably a planar and circular disk; however, it is not limited to this configuration. It has several features that enable it to be easily coupled to the wheel assembly. These features include several narrow slots or cuts 220 that extend radially from the periphery of the base inward toward the center of the base. Several slots 220 (preferably three or four) are preferably provided in base 204 . They are preferably spaced equidistantly around the periphery of the base. In addition to slots 220 , base 204 has a series of holes 222 , preferably three or four (as shown here), that are positioned equidistant from the periphery of base 204 and preferably in a symmetrical pattern. Base 204 also has a central hole 224 that, like slots 220 and holes 222 , extends completely through the base. Base 204 is preferably made of a lightweight metal or metal alloy. It may also be formed of a polymer or plastic that may be fiber reinforced, such as by carbon fibers. Other lightweight and durable materials may also be used. Base 204 is preferably between 1½ and 5 inches across.
[0052] Shaft 206 is fixed (preferably welded or swaged) to base 204 . It is coupled to and between base 204 and unit base 104 of upper section 202 . Shaft 206 is hollow and cylindrical defining a central aperture 226 that extends the length of the shaft. Shaft 206 is coupled to base 204 such that a continuous passageway is formed that extends completely through central hole 224 and aperture 226 of shaft 206 , extending completely through base 204 and shaft 206 . Shaft 206 is preferably mounted perpendicular to base 204 and fixed to the center of base 204 . It is preferably constructed of lightweight metal or metal alloy, but may also be formed of a plastic or polymer that may be reinforced, such as by carbon fiber. Other lightweight and durable materials may also be used.
[0053] Upper section 202 of wheel illumination device 100 includes a unit base 104 and a cap or cover 106 that encloses the unit base defining a hollow cavity. Upper section 202 also includes lights 110 ( FIGS. 1, 16 , 18 - 19 ), electronics box 214 ( FIG. 5 ), and rechargeable batteries 216 ( FIG. 5 ). The lights, electronics box and rechargeable batteries or disposed inside the hollow cavity formed by unit base 104 and cap or cover 106 . Upper section 202 also includes solar panel 112 that is fixed to the outside of cap or cover 106 .
[0054] Referring to FIGS. 2, 4 and 5 , unit base 104 has a planar bottom 228 coupled to a cylindrical wall 230 . Bottom 228 has a central hole 232 . Unit base 104 is coupled to shaft 206 by inserting a shaft 206 through central hole 232 and tightening jam nuts 233 on either side of bottom 228 . When unit base 104 is fixed to shaft 206 in this manner, bottom 228 is parallel to base 104 and perpendicular to shaft 206 . To assemble unit base 104 to shaft 206 , the operator first places a jam nut 233 on shaft 206 . The operator then inserts the free end of shaft 206 into and through central hole 232 . The operator then threads a second jam nut 233 on to the free end of shaft 206 , and tightens the jam nuts together.
[0055] Retaining rings are preferably used in place of jam nuts 233 if shaft 206 is not threaded. Unit base 104 can be positioned either closer to or farther from base 204 (coupled to the wheel) by adjusting the relative position of jam nuts 233 . This is particularly valuable when adjusting the wheel illumination device 100 to an optimum position that will most pleasingly illuminate the wheel.
[0056] Bottom 228 has several holes 234 that extend completely through bottom 228 . These holes provide electrical access to a series of illumination systems, such as lights 110 . There are preferably at least four holes 234 distributed equally about the periphery of bottom 228 and adjacent an outer edge of bottom 228 . Each of holes 234 supports at least one associated light 110 . These lights are preferably LEDs, although other illumination sources may be used. Bottom 228 is preferably larger than the diameter of base 204 .
[0057] Unit base 104 is supported on the end of shaft 206 . In the preferred embodiment, it is free to rotate with respect to shaft 206 , and preferably to stay stationary as the automobile 98 travels down the road and the wheel (and shaft 206 fixed to the wheel) rotates. This free rotation of unit base 104 is provided by bearing 236 , which is fixed to bottom 228 and defines central hole 232 . When shaft 206 is fixed to bottom 228 , with jam nuts, it is fixed to bearing 236 . Bearing 236 , in turn, is fixed to bottom 228 . Bearing 236 is preferably a sealed bearing, it may also be an oil impregnated brass fitting. By this arrangement, unit base 104 rotates with respect to shaft 206 .
[0058] Cylindrical wall 230 preferably has a thickness of between 1 and 5 mm and is preferably about ½” to 2 inches in height. Wall 230 has a series of openings or holes 238 . These holes are positioned generally vertically with respect to the planar surface of bottom 228 . This enables various height positions.
[0059] FIG. 5 is a plan view of the open end 240 of unit base 104 with cover 106 and shaft 206 removed. Unit base 104 supports lights 110 , electronics box 214 , and rechargeable batteries 216 . Lights 110 are electrically coupled to electronics box 214 , which is electrically coupled to batteries 216 , which, in turn, may be electrically coupled to generator 282 and/or solar panel 112 .
[0060] Electronics box 214 is preferably secured to the inside of bottom 228 and is positioned off center. This provides room to fix jam nut 233 ( FIG. 2 ) onto shaft 206 inside unit base 104 . It also provides an off-center counterweight inside the upper section 202 that tends to keep the upper section 202 from rotating. Alternatively, electronics box 214 may be attached to the inside of cylindrical wall 230 or to the inside of cover 106 (preferably off-center).
[0061] Electronics box 214 contains a modular circuit board (with circuitry shown in FIG. 20 ), which controls the functions of the wheel illumination system. Box 214 receives its electrical power from wiring harness 242 . Wiring harness 242 is coupled to rechargeable batteries 216 . Box 214 emits an electrical charge into wiring harness 244 . Wiring harness 244 is coupled to four lights 110 , each light 110 being mounted in and supported by a corresponding hole 234 . Lights 110 face outwards, toward the wheel.
[0062] Rechargeable batteries 216 are preferably secured to bottom 228 of base 104 . Batteries 216 are positioned off center, like electronics box 214 , and for the same reason. Alternatively, batteries 216 may be attached to the inside surface of cylindrical wall 230 , or alternatively to the inside of cover 106 (preferably off-center). Batteries 216 may alternatively be coupled to upper section 202 in any position that allows the weight of the batteries to counterweight the upper section to control the amount of rotation as the wheel rotates and the automobile 98 travels down the road.
[0063] Referring back to FIG. 2 , upper section 202 further includes a seal 246 that is generally circular and preferably made of rubber. Seal 246 is placed over the outside of cylindrical wall 230 and placed in either of two shallow grooves 248 . Grooves 248 are circular and extend around the outside of cylindrical wall 230 . Grooves 248 are spaced approximately a half an inch apart. Each groove 248 is parallel to bottom 228 of unit base 104 . Holes 234 are formed in the cylindrical wall 230 adjacent to each of parallel grooves 248 . Holes 234 are on the side of grooves 248 closer to bottom 228 .
[0064] Cover 106 includes a cylindrical wall 250 that is slightly larger in diameter than cylindrical wall 230 of unit base 104 . The height of wall 250 is preferably between 1 and 3 inches. Several holes 252 are formed in cylindrical wall 250 that correspond in location with holes 238 in cylindrical wall 230 or preferably equal in number to holes 238 .
[0065] Holes 252 and holes 238 are disposed and can be aligned such that fasteners 108 such as bolts, screws or rivets can be inserted into holes 252 and into holes 238 to removably fix cover 106 to unit base 104 . Cylindrical wall 250 is sized to cover cylindrical wall 230 and abut seal 246 . Seal 246 prevents water and other contaminants from leaking into upper section 202 between unit base 104 and cover 106 .
[0066] Referring now to FIGS. 6-9 , alternative covers 106 include a top 254 that extends across and encloses cylindrical wall 250 . Top 254 may have various shapes, such as those shown in FIGS. 6-9 , including a flat top ( FIG. 6 ), a rounded top ( FIG. 7 ), a four-pointed spinner ( FIG. 8 ) and a three-pointed spinner ( FIG. 9 ).
[0067] The outside diameter of cover 106 is preferably between 3 inches and 8 inches. Cover 106 is preferably composed of a lightweight metal or metal alloy, although various types of plastics or carbon fiber reinforced plastics may be used. Cover 106 is preferably reflective, having a chrome, chrome-plated, brushed, or polished aluminum finish. In the alternative, it may also be painted with visually pleasing paints such as metallic paints and fluorescent paints. It may also have patterns or designs on its outer surface.
[0068] Illumination sources or lights 110 can be coupled directly to holes 234 , or alternatively, they can be mounted to holes 234 using light mounts, such as those light mounts shown in FIGS. 10-13 . Examples of these light mounts as installed can be found in FIG. 1,16 , 18 , and 19 .
[0069] FIG. 10 shows a swiveling light mount 256 having a collar 258 that is fixed in hole 234 , and a flexible shaft 260 to which light 110 is coupled. FIG. 11 shows a gooseneck light mount 262 including a collar 264 that is fixed in hole 234 , and a flexible shaft 266 to which light 110 is coupled. FIG. 12 shows up a tubular light mount 268 having a collar 270 that is fixed to hole 234 and an elongated tubular shaft 272 to which light 110 is coupled. FIG. 13 shows an extension tube light mount 274 that includes a collar 276 from which two nested tubes 278 , 280 extend. Tubes 278 , 280 are nested, with tube 280 nested inside tube 278 . Tube 280 can be extended from tube 278 by pulling gently on the end of tube 280 . Light 110 is fixed to the end of tube 280 such that it can be extended and retracted whenever tube 280 is extended and retracted.
[0070] In each of the examples of FIGS. 10-13 , light 110 is preferably an LED that extends outward away from its associated light mount and hole 234 , directing light outward away from device 100 and toward the wheel to which device 100 is mounted. These lights provide illumination for the wheel. Electrical power is provided to each of lights 110 in FIGS. 10-13 by wires (not shown) that are coupled to lights 110 , that extend through the light mounts and that pass through holes 234 in bottom 228 . FIG. 5 shows how electricity is carried to each of holes 234 . Each of the lights is electrically connected to the modular circuit board of electronics box 214 by wiring harness 244 .
[0071] In an alternative embodiment, lights 110 , and light mounts 256 , 262 , 268 , 274 may be disposed in a similar matter on any or all of cover 106 , wall 230 , and wall 250 as they are on bottom 228 . In another alternative arrangement, lights 1110 need not be fixed to the outside of upper section 202 , but may be mounted inside upper section 202 as well. In this configuration, holes may be provided in the walls of upper section 202 , such as holes 234 in bottom 228 or other holes formed in unit base 104 or cover 106 , through which light from lights 1110 located inside upper section 202 radiate.
[0072] Referring back to FIG. 2 , solar panel 112 is preferably fixed to the outer surface of top 254 of cover 106 , with electrical wires from solar panel 112 passing through an opening (not shown) in cover 106 . These wires are also coupled to rechargeable batteries 216 (see FIG. 5 ). Solar panel 112 is preferably circular, as shown in FIG. 2 , although it may be square or have an irregular shaped boundary. While a single solar panel is preferred, one or more solar panel 112 may be employed.
[0073] The generator 282 is the power source of the device. The power supply is from the generator 282 with the solar panel 112 as the alternative, or can be used in addition to the generator 282 .
[0074] The power source is shown FIGS. 14-15 . The power source includes a generator 282 which supplies electricity to lights 110 and serves to recharge batteries 216 . In FIGS. 14-15 , the electronics box, lights, and wiring harnesses (shown in FIG. 5 ) have been removed to better show the arrangement of generator 282 to unit base 104 .
[0075] Generator 282 is mounted inside bottom 228 of unit base 104 . The stator of generator 282 is coupled to bottom 228 by adjustable mounting brackets 284 , which allow for various sizes of gears. Generator 282 has a rotor with a generator shaft 286 on which a generator gear 288 is mounted. Generator gear 288 , in turn, is engaged to shaft gear 290 , which is fixed to shaft 206 . Shaft 206 rotates with respect to upper section 202 whenever the vehicle is moving.
[0076] When the vehicle is moving, the wheel assembly rotates. When the wheel assembly rotates, it rotates lower section 200 , which is fixed to the wheel assembly. Shaft 206 of lower section 200 rotates as the vehicle moves. Upper section 202 , however, does not rotate or rotates less than the rotation of the lower section 200 when the vehicle moves. Upper section 202 is eccentrically weighted by the off-center location of one or more of its internal components (the batteries, generator, and electronics box) or by the addition of special weights (not shown). Since upper section 202 is supported on a bearing and it is eccentrically weighted it does not rotate.
[0077] Since shaft 206 rotates and upper section 202 does not rotate or rotates less than the rotation of the lower section 200 when the vehicle moves, relative motion between shaft 206 and a generator is provided. Shaft gear 290 turns generator gear 288 and drives the generator. When the generator is driven, it provides electricity to the electronics box and the batteries 216 to which it is connected by power supply leads 291 . The relative sizes of gears 288 and 290 can be varied to provide the desired electrical output.
[0078] There are several preferred methods for attaching wheel illumination device 100 to wheel assembly 114 . These are illustrated in FIGS. 16-19 herein.
[0079] In the first of these arrangements, shown in FIG. 16 , lower section 200 is fixed to the center of a hubcap (or hub cover) 292 . Hubcap 292 can be one provided by the automobile 98 manufacturer, or it may be a custom aftermarket hubcap. Hubcap 292 is fixed to wheel assembly 114 in the conventional manner. Fasteners 294 extend through holes 222 in base 204 to a lower better fit to surface being attached to if needed (such as concave or convex). The fasteners go through holes 222 . Fasteners 294 , in turn, pass through corresponding holes 296 in hubcap 292 , and are fixed thereto by nuts 298 threaded onto the free end of fasteners 294 . Before tightening nuts 298 , the operator adjusts the position of lower section 200 until shaft 206 of lower section 200 is coaxial with the axis of rotation of wheel assembly 114 . The operator then tightens nuts 298 . Holes 296 in hubcap 292 may be made by the aftermarket installer of wheel illumination system 100 on hubcap 292 . Slots 220 provide base 204 with some limited flexibility, permitting it to conform more easily with irregularly shaped hubcaps 292 .
[0080] In a second arrangement, shown in FIG. 18 , a universal attachment plate 300 ( FIG. 17 ) is fixed to the free ends of lug nuts 302 of wheel assembly 114 . Base 204 of lower section 200 is subsequently fixed to plate 300 . Upper section 202 is subsequently fixed to lower section 200 .
[0081] If the automobile 98 has one, the existing hubcap on the vehicle is removed and universal attachment plate 300 replaces it. Plate 300 has a plurality of holes 304 that are disposed about its periphery. These holes are selected and disposed to match several different lug nut patterns on a variety of automobiles.
[0082] Universal attachment plate 300 is formed as a series of two (shown here) or three concentric rings, each of said rings having a plurality of holes 304 arranged to match different lug nut patterns. For larger vehicles with wider spaced lug nuts, plate 300 can be fixed to lug nuts 302 by bolts 306 passing through holes 304 in the outer concentric ring 308 . For smaller vehicles with closely spaced lug nuts, plate three can be fixed to lug nuts 302 by bolts 306 passing through holes 304 in the inner concentric ring 310 . In the event inner concentric ring 310 is fixed to lug nuts, outer concentric ring 308 can be removed by sawing through tabs 312 that couple the inner and outer concentric rings. The figures herein show two concentric rings that are connected by tabs 312 . In an alternative embodiment, an additional one or two concentric rings can be provided to match even larger lug nut patterns.
[0083] Lug nuts 302 can be standard lug nuts provided by the automobile 98 manufacturer, or they can be custom lug nuts that are provided as an aftermarket product. The distance plate 300 is spaced away from wheel assembly 114 can be varied by selecting lug nuts of greater or lesser length. Longer or “extension” lug nuts are preferred.
[0084] Base 204 is attached to plate 300 using threaded fasteners 294 . Fasteners 294 extend through holes 222 in base 204 . Fasteners 294 , in turn, pass through corresponding holes 304 in plate 300 , and are fixed thereto by nuts 298 that are threaded onto the free end of fasteners 294 . Before tightening nuts 298 , the operator adjusts the position of lower section 200 until shaft 206 is coaxial with the axis of rotation of wheel assembly 114 . The operator then tightens nuts 298 .
[0085] In a third arrangement, shown in FIG. 19 , base 204 is not fixed directly to plate 300 , but is spaced away from plate 300 by hub cover 316 . Hub cover 316 is provided for use in situations when the hub of wheel assembly 114 extends outward away from the wheel too far to permit base 204 to be attached to directly to plate 300 .
[0086] Hub cover 316 is a hollow right circular cylindrical body 318 having a first enclosed end 320 and a circular flange 322 extending radially outward from a second end of body 318 about the entire circumference of body 318 . Flange 322 is planar and is fixed to plate 300 with threaded fasteners 294 . Fasteners 294 extend through holes 324 in flange 322 , and then through corresponding holes 314 in plate 300 . Nuts 298 are threaded onto the free end of fasteners 294 and are tightened. This arrangement fixes hub cover 316 to plate 300 .
[0087] Base 204 is attached to hub cover 316 using threaded fasteners 294 . Fasteners 294 extend through holes 222 in base 204 . Fasteners 294 , in turn, pass through corresponding holes 326 in first enclosed end 320 of hub cover 316 , and are fixed thereto by nuts 298 that are threaded onto the free end of fasteners 294 inside hub cover 316 .
[0088] Before tightening nuts 298 inside hub cover 316 , the operator adjusts the position of lower section 200 until shaft 206 is coaxial with the axis of rotation of wheel assembly 114 . The operator then tightens nuts 298 .
[0089] FIG. 20 is a schematic illustrating the control circuit 330 formed on the modular circuit board in the electronics box, together with the power source and battery. The core of the control circuit 330 is microprocessor 332 , which controls the operation of the entire control circuit. Microprocessor 332 is coupled to a radio receiver 334 for receiving remote commands that control the device 100 , a speed sensor 336 , power conversion and conditioning circuitry 338 , lighting power conversion circuitry 340 , and lighting control circuitry 342 . Lights 110 are coupled to lighting control circuitry 342 from which they receive their electrical signals and responsively generate light. Control circuit 330 also includes a power storage circuit 344 which includes rechargeable batteries 216 . Power storage circuit 344 is coupled to power conversion and conditioning circuit 338 . Solar panel 112 and generator 282 are also coupled to power conversion and conditioning circuit 338 to provide electrical power to the control circuit and the lights. Power transfer system 346 is also coupled to power conversion and conditioning circuit 338 to control the direction and flow of electrical power to and from the batteries 216 , the generator 282 , the solar panel 112 , and the microprocessor 332 .
[0090] Microprocessor 332 receives its power from power conversion and conditioning circuit 338 . Power conversion and conditioning circuit 338 regulates the electricity supplied by solar panel 112 and power generator 282 , as well as power storage circuit 344 . As power is used by the power storage circuit 344 , power conversion and conditioning circuit 338 directs electrical power from power generator 282 and solar panel 112 to power storage circuit 344 .
[0091] Microprocessor 332 is configured to receive speed signals from speed sensor 336 . Microprocessor 332 is also configured to receive commands from radio receiver 334 , which in turn receives commands from the operator in the automobile 98 (see FIG. 21 , below).
[0092] In response to these commands, microprocessor 332 is configured to control the direction and amount of electrical power provided to lights 110 . Microprocessor 332 does this by signaling lighting control circuit 342 . Lighting control circuit 342 regulates the flow of electricity from lighting power conversion circuit 340 . Lighting power conversion circuit 340 regulates the voltage of the electrical power provided by power conversion and conditioning circuit 338 to a level that is compatible with lights 110 .
[0093] Microprocessor 332 is programmed to selectively generate different patterns of light emitted by lights 110 . It does this by calculating the duration and intensity of light that is required from lights 110 and signaling lighting control circuit 342 accordingly. Microprocessor 332 is preprogrammed to generate several patterns when requested by the user via radio receiver 334 .
[0094] Microprocessor 332 is programmed to change the color of lights 110 by turning lights 110 of one color off and turning lights 110 of another color on. Microprocessor 332 is programmed to flash lights 110 by turning them on and off at a preprogrammed interval. Microprocessor 332 is further programmed to fairy the preprogrammed interval at which it turns the lights on and off. Microprocessor 332 is programmed to monitor speed sensor 336 and determine when the automobile 98 is stationary or moving at a predetermined speed. Microprocessor 332 is programmed to turn lights 110 off when the vehicle and the wheel assembly are stationary. Microprocessor 332 is also programmed in another mode of operation to turn lights 110 on when the vehicle and the wheel assembly start moving. Microprocessor 332 is also programmed to turn lights 110 on when the vehicle and the wheel assembly begin moving. Microprocessor 332 can change the speed of the patterns automatically by monitoring the speed of the vehicle and the wheel assembly using speed sensor 336 . Microprocessor 332 is programmed to vary the light intensity with the volume of a sound signal provided by the user via radio receiver 334 . In this manner, microprocessor 332 is configured to change the intensity of the plurality of lights 110 in synchrony with an audio source transmitted from the user to control circuit 330 via radio receiver 334 .
[0095] In FIG. 21 we see a remote control system 364 configured to transmit operator commands and audio signals to wheel illumination system 100 via a radio transmitter 354 ( FIG. 20 ). Remote control system 364 includes a microprocessor 348 that receives operator mode selections from mode selection input device 350 , and receives an audio signal from sound conditioning and conversion circuit 358 . In response to these signals, microprocessor 348 transmits light command signals to radio transmitter 354 . Radio transmitter 354 , in turn, transmits these light command signals to radio receiver 334 (see FIG. 20 ) of the wheel illumination system 100 . When radio receiver 334 receives these signals, it transmits them to microprocessor 332 of wheel illumination system 100 , which responsively commands lighting control circuit 342 to generate the requested light patterns. In this manner, the user (who is preferably inside the operator's compartment of the automobile 98 ) can change the mode of operation of the wheel illumination system 100 and the patterns of light generated by lights 110 in real time as the automobile 98 travels down the road.
[0096] The user or operator communicates with microprocessor 348 by entering commands into mode selection input device 350 . Mode selection input device 350 is preferably a touch screen display, incorporating a screen (status display 352 ) and a pressure sensitive transparent switching surface (mode selection input device 350 ). As the operator presses the touch screen, microprocessor 348 presents the user with a series of menus that are displayed on the touch screen. The operator can select whether to (1) turn the lights off, (2) turn the lights on, (3) turn the lights off automatically when the vehicle stops moving, (4) turn the lights on automatically when the vehicle stops moving, (5) turn the lights on automatically when the vehicle starts moving, (6) transmit sound intensity signals from a microphone 362 to the wheel illumination system 100 , (7) transmit sound intensity signals from an external audio input 360 (from an audio source such as car stereo, car CD, satellite radio, terrestrial radio or the like) to the wheel illumination system 100 , (8) select a desired color for lights 110 , (9) select a desired rate at which to flash or blink lights 110 .
[0097] The two microprocessors shown herein are preferably Microchip PIC microprocessors or Amtel. The patterns are stored in the NVRAM of the PIC microprocessors. The user selects the patterns from the touch screen/selection menu of the remote control system. The user selects specific colors by selecting predetermined modes of operation from the touch screen. Using the speed sensor, the wheel unit could time the pulses of light so as to create the illusion of the wheels rotating in either a counterclockwise or clockwise pace. The user selects specific colors by selecting predetermined modes of operation from the touch screen or selects custom color schemes using the same interface. To create a new pattern the user selects them using the remote control system, or downloads new patterns into the controller. The power may be provided by a power transit options system (e.g. a magnetic induction power systems such as used for security cards and rechargeable toothbrushes) or direct connect systems (rotor on back of wheel with contacts). The transmitter and receiver communicate over radio frequencies. Alternatively, other electromagnetic data link methods may be used as well these other methods within the electromagnetic spectrum include infrared and magnetic inductance data links.
[0098] One will appreciate that the present disclosure is intended as an exemplification of the invention, and is not intended to limit the invention to the specific embodiment illustrated. The disclosure is intended to cover by the appended claims all such modifications as fall within the scope of the claims. | A system for illuminating a motor vehicle wheel assembly of a motor vehicle is provided, the system including a mount configured to be fixed to the wheel assembly, a plurality of lights fixed to the mount, a control circuit coupled to the plurality of lights to regulate a flow of electricity to the plurality of lights; and a power source coupled to the control circuit to provide said control circuit with electrical power for the lights, wherein the power source includes an electrical energy generating element as well as an electrical energy storing element. | 54,658 |
BACKGROUND OF THE INVENTION
[0001] This application claims the priority of Korean Patent Application No. 2004-0059245, filed on Jul. 28, 2004, 2004-0059246, filed on Jul. 28, 2004, 2004-0067536, filed on Aug. 26, 2004 and 2004-0118158, filed on Dec. 31, 2004 in the Korean Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference.
[0002] 1. Field of the Invention
[0003] The present invention relates to a polishing slurry, particularly, a slurry for chemical mechanical polishing (hereinafter, referred to as ‘CMP’), which is used in a chemical mechanical polishing process for flattening a semiconductor laminate. More particularly, the present invention pertains to a method of producing a slurry which has high removal selectivity to a nitride layer used as a barrier film in a shallow trench isolation CMP process needed to fabricate ultra highly integrated semiconductors of 256 mega D-RAM or more (Design rule of 0.13 μm or less) and which decreases the occurrence of scratches on a flattened surface, and a method of polishing a substrate using the same.
[0004] 2. Description of the Related Art
[0005] Chemical mechanical polishing (CMP) is a semiconductor processing technology in which a mechanical process using polishing particles between a pressed wafer and a polishing pad and chemical etching using a slurry are simultaneously conducted, and has been an essential process of global planarization technology in the production of submicron-scaled semiconductor chips since IBM Co., Ltd. in the USA developed it at the end of the 1980's.
[0006] The types of slurry are roughly classified into a slurry for oxide, a slurry for metal, and a slurry for poly-silicon according to the type of object to be polished. The slurry for oxide is used to polish an interlayer insulating film and a silicon oxide (SiO 2 ) layer employed in an STI (shallow trench isolation) process, and roughly comprises polishing particles, deionized water, a pH stabilizer, and a surfactant. The polishing particles function to mechanically polish the surface of the object by means of pressure from a polishing machine, and are exemplified by silica (SiO 2 ), ceria (CeO 2 ), and alumina (Al 2 O 3 ).
[0007] Particularly, ceria slurry is frequently used to polish the silicon oxide layer during the STI process, and in this case, a silicon nitride layer is mainly used as a polishing stopper layer. Hence, an additive is added to the ceria slurry to reduce the removal speed of the nitride layer so as to improve the polishing speed selectivity of the oxide layer to the nitride layer. However, the use of the additive is disadvantageous in that the removal speed of the oxide layer, as well as the removal speed of the nitride layer, is reduced. Furthermore, the polishing agent of the ceria slurry typically has particles larger than those of the silica slurry, and therefore scratches the surface of the wafer.
[0008] However, if polishing speed selectivity of the oxide layer to the nitride layer is low, a dishing phenomenon, in which an excessive volume of the oxide layer is removed, occurs due to the loss of adjacent nitride layer patterns. Thus, it is impossible to achieve uniform surface flattening.
[0009] Accordingly, the slurry for STI CMP requires high selectivity and polishing speed, dispersion and micro-scratch stabilities, and narrow and uniform particle size distribution. Additionally, the number of large particles having the size of 1 μm or more must exist within a predetermined range.
[0010] With respect to conventional technology of producing the slurry for STI CMP, U.S. Pat. Nos. 6,221,118 and 6,343,976, granted to Hitachi Inc., disclose a method of synthesizing ceria particles and a method of producing a slurry having high selectivity using the same. These patents describe characteristics of particles required in the slurry for STI CMP, the type of additives containing polymer, and the production method using them in very critical and wide ranges. Particularly, the patents suggest wide ranges of an average grain size, an average primary particle size, and an average secondary particle size. Particularly, they mention a change of the grain size depending on calcination temperature, and scratches corresponding to this. In another conventional technology, U.S. Pat. No. 6,420,269, granted to Hitachi Inc., discloses a method of synthesizing various ceria particles and a method of producing a slurry having high selectivity using the same. Meanwhile, U.S. Pat. No. 6,615,499, granted to Hitachi Inc., discloses a change of ratios of peak intensities in a predetermined range of X-rays, which depends on a rate of temperature increase in a calcination process, and a change of a removal rate according to this. Furthermore, in the prior arts, U.S. Pat. Nos. 6,436,835, 6,299,659, 6,478,836, 6,410,444, and 6,387,139, which have been made by Showa Denko Co. Ltd. in Japan, disclose a method of synthesizing ceria particles and a method of producing a slurry having high selectivity using the same. These patents mostly describe the types of additives added to the slurry, effects due to them, and a coupling agent.
[0011] However, the above prior arts disclose only the average particle size of the polishing particles constituting the polishing slurry and the range thereof, but lack details on how to disperse the particles. If it is considered that a dispersion state and a particle size distribution of ceria powder are very remarkably dependent on the degree of improvement of properties and dispersion stability thereof, and that, therefore, the degree of improvement significantly affects the number of micro-scratches, it becomes very important to find process conditions capable of assuring optimum dispersion stability using properties and dispersion of the ceria powder, which depend on calcination conditions. Furthermore, it is very important to find process conditions capable of assuring optimum dispersion stability by mixing with an appropriate amount of dispersing agent and using dispersing devices, and to provide a slurry formed through the resultant process.
SUMMARY OF THE INVENTION
[0012] Accordingly, the present invention has been made keeping in mind the above problems occurring in the prior art, and an object of the present invention is to provide a high performance nano ceria slurry which is capable of being applied in a process of producing ultra highly integrated semiconductors of 0.13 μm or less, particularly, an STI process, and is capable of minimizing micro-scratches that are fatal to semiconductor devices by properly employing a method and a device for pre-treating various particles, a dispersing device and a method of operating the dispersing device, a method of adding a chemical additive and an amount added, and a device for transferring samples.
[0013] Particularly, the present invention discloses a change of surface areas of polishing particles by controlling calcination conditions, and a change of dispersion stability according to this in a process of producing powder used as a raw material of a slurry.
[0014] Furthermore, where ceria powder and deionized water (DI water) are mixed to produce a slurry, it discloses a change of dispersion stability when dispersion stabilization is conducted using dispersion devices by controlling an optimum amount of a dispersing agent added depending on pH of the slurry and controlling a stage at which the dispersing agent is added.
[0015] Based on the above description, the present invention aims to provide a slurry that is capable of minimizing micro-scratches and maintaining a suitable removal rate and in which dispersion is stabilized.
[0016] Another object of the present invention is to provide a method of effectively polishing a semiconductor substrate having a fine design rule using the above slurry.
[0017] In order to accomplish the above objects, the present invention provides a polishing slurry which comprises polishing particles in which a surface area per unit weight is changed so as to minimize agglomeration of the polishing particles and improve dispersion stability.
[0018] The surface area per unit weight of the polishing particles may be 1-100 m 2 /g, preferably 3-72 m 2 /g, and more preferably 5-25 m 2 /g. A grain size of each of the polishing particles may be 15-40 nm, preferably 18-30 nm, and more preferably 20-25 nm.
[0019] The surface area per unit weight of the polishing particles may be controlled depending on a temperature or a holding time of a calcination process.
[0020] The present invention provides a polishing slurry, which comprises polishing particles, deionized water, and a dispersing agent and in which agglomeration of the polishing particles is minimized and a variation (dD50) of a median particle size of the polishing particles is 30 or less before and after forcible dispersion treatment, by controlling an amount of dispersing agent added or a stage at which the dispersing agent is added. It is preferable that the variation (dD50) of the median particle size of the polishing particles be 10 or less. Conductivity of the polishing slurry is preferably 300-900 μs/cm, and more preferably 500-600 μs/cm. The dispersing agent is made of an anionic polymer compound, and the anionic polymer compound may be at least one selected from a group consisting of polymethacrylic acid, polyacrylic acid, ammonium polymethacrylate, ammonium polycarboxylate, and carboxyl-acryl polymer.
[0021] The polishing particles include ceria.
[0022] Furthermore, the present invention provides a method of producing a polishing slurry. The method comprises preparing polishing particles, deionized water, and a dispersing agent; preparing a mixture of the polishing particles, the deionized water, and the dispersing agent; and milling the mixture of the polishing particles, the deionized water, and the dispersing agent.
[0023] The preparation of the mixture of the polishing particles, the deionized water, and the dispersing agent may comprise milling a mixture of the polishing particles and the deionized water; measuring a pH of the mixture of the polishing particles and the deionized water; determining an amount of dispersing agent to be added, depending on the pH; and mixing the dispersing agent with the mixture of the polishing particles and the deionized water.
[0024] In the determination of the amount of dispersing agent, the amount of dispersing agent added is 2.2-3.0 wt % based on the polishing particles when the pH of the mixture of the polishing particles and the deionized water is 8.7-9.5, 1.4-2.2 wt % based on the polishing particles when the pH of the mixture of the polishing particles and the deionized water is 8.0-8.7, and 0.6-1.4 wt % based on the polishing particles when the pH of the mixture of the polishing particles and the deionized water is 7.4-8.0.
[0025] The preparation of the mixture may comprise adding the dispersing agent to the deionized water and mixing them; and mixing the polishing particles with the deionized water to which the dispersing agent is added.
[0026] Furthermore, the preparation of the mixture may comprise adding the polishing particles to the deionized water; and mixing the dispersing agent with the deionized water to which the polishing particles are added.
[0027] Additionally, the preparation of the mixture may comprise adding the dispersing agent and the polishing particles to the deionized water and mixing them.
[0028] The milling of the mixture of the polishing particles, the deionized water, and the dispersing agent may comprise additionally adding the dispersing agent at least one time. The dispersing agent is added in an amount of 0.0001-10 wt % based on the polishing particles in such a way that the dispersing agent added in deionized water is an amount of 100-50% based on a total amount of dispersing agent, and that the dispersing agent added in the course of milling the mixture is an amount of 50% or less based on the total amount of dispersing agent.
[0029] The preparation of the polishing particles, the deionized water, and the dispersing agent may comprise producing the polishing particles through a calcination process at a predetermined calcination temperature for a predetermined holding time. The calcination temperature is 500-1000° C. and the holding time is 10 min-10 hours at the calcination temperature in the production of the polishing particles.
[0030] The production of the polishing particles may comprise preparing a crude precursor; removing water of crystallization and adsorbed water; removing a carbonate functional group; and conducting recrystallization. The crude precursor includes cerium carbonate.
[0031] The method may further comprises adding an additive, including a weak acid or a weak base, to the mixture to control a pH of the slurry; and conducting filtering to remove large particles, after the milling of the mixture of the polishing particles, the deionized water, and the dispersing agent.
[0032] As well, the present invention provides a method of polishing a predetermined substrate using the above-mentioned polishing slurry.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] The above and other objects, features and advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
[0034] FIG. 1 is a flow chart illustrating the production of a slurry according to the present invention;
[0035] FIG. 2 schematically illustrates a polishing mechanism of a ceria polishing agent;
[0036] FIG. 3 illustrates a definition of D50 depending on particle size;
[0037] FIG. 4 is a TEM picture of polishing particles calcined at 700° C. for 2 hours;
[0038] FIG. 5 is a TEM picture of polishing particles calcined at 700° C. for 4 hours;
[0039] FIG. 6 illustrates adsorption of a dispersing agent depending on pH; and
[0040] FIG. 7 illustrates surface electric potentials of ceria slurry before and after the dispersing agent is added.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0041] Hereinafter, a process of producing a polishing slurry according to the present invention and a characteristic analysis of the polishing slurry will be separately described in detail. Furthermore, a description will be given of a method of producing the polishing slurry using ceria as a polishing agent, deionized water as a dispersion medium thereof, and an anionic polymer dispersing agent as a dispersing agent. Additionally, a description will be given of the CMP results, such as an oxide film polishing speed and selectivity, depending on process conditions. Many modifications and variations of the present invention, which will be described later, are possible, and the scope of the present invention is not limited by the following description.
[0042] [Production of Ceria Slurry]
[0043] The ceria slurry of the present invention is produced so as to contain ceria powder, deionized (DI) water, anionic polymer dispersing agent, and an additive such as a weak acid or weak base. A method of producing the polishing ceria slurry comprises the following steps (see FIG. 1 ).
[0044] First, a precursor, such as cerium carbonate, is pre-treated. That is to say, it is synthesized in a solid phase to prepare the ceria powder (S 1 ). The ceria powder is mixed and wetted with deionized (DI) water in a tank for mixing (S 2 ), and the resulting mixture is milled using a milling machine so as to decrease the particle size and achieve distribution (S 3 ). The anionic polymer dispersing agent is added to the slurry, which is produced according to the above procedure, to increase dispersion stability (S 4 ), and the additive, such as the weak acid or weak base, is mixed with the mixture in a high speed mixer to control the pH. Subsequently, additional milling is conducted to stabilize the dispersion (S 5 ) so that the weight ratio (wt %) of the slurry, that is, the solid load, is desirably set (S 6 ), large particles are removed through filtering to prevent the occurrence of scratches during precipitation and polishing (S 7 ), and additional aging is conducted, thereby the slurry is stabilized (S 8 ). The method of producing the polishing ceria slurry according to the present invention will be stepwise described in detail.
[0045] 1. Production of Ceria Powder
[0046] A first stage of the production of the ceria slurry according to the present invention is to produce the ceria powder from a crude precursor through a solid-phase synthesis method. For example, the precursor, such as cerium carbonate, is calcined to generate the ceria powder, and a separate drying process may be conducted to remove moisture before the calcination. The dried precursor is excellent in terms of transferring and processibility.
[0047] Properties of the ceria powder depend on the calcination conditions of cerium carbonate and the construction of a calcination device. Cerium carbonate has water of crystallization and adsorbed water, and water of crystallization typically has a valence of 4, 5, or 6. The calcination conditions depend on the number of water of crystallization and the amount of adsorbed water. After the calcination, water of crystallization and adsorbed water are removed. Thereafter, temperature and heat treatment are increased to cause decarbonation, in which a carbonate functional group is removed in the form of carbon dioxide. Thereby, the ceria powder starts to be generated. Next, additional heat treatment is implemented to cause recrystalization, thereby creating the ceria powder, which consists of various sizes of particles. It is preferable that the calcination be conducted at 500-1000° C.
[0048] Crystallinity, the grain size, and the surface area per unit weight depend on the calcination temperature and a holding time of the process. As the calcination temperature and the holding time increase, the grain size or a size of one crystal increases but the surface area is reduced. The related details will be described later.
[0049] 2. Mixing and milling
[0050] The ceria powder, which is produced through the process as described above, is mixed and wetted with deionized water in a high speed mixer. Subsequently, the mixture is milled to reduce the particle size and disperse particles, thereby a nano-sized ceria slurry is produced.
[0051] After the above mixing and wetting, it is preferable that particle size reduction and distribution be conducted using a high energy milling machine so as to control the particle size and to distribute agglomerated polishing particles. The milling machine may be exemplified by a wet or dry milling machine. The dry milling machine may be contaminated by metal pieces caused by the abrasion of metal portions during the milling process, thus it is preferable to conduct the milling process using a wet milling machine made of ceramic. Meanwhile, when using a wet milling process, precipitation and reduction of milling efficiency may occur, and the presence of large particles and a size distribution having a large area may be likely due to agglomeration of the particles, thus it is necessary to control the concentration of the polishing particles, to control a pH and conductivity, and to increase dispersion stability using a dispersing agent. In the present invention, it is preferable to conduct pass-type milling at least three times.
[0052] 3. Dispersion Stabilization and Addition of an Additive
[0053] An anionic polymer dispersing agent is added to the slurry, and the additive, such as the weak acid or weak base, is added thereto to control a pH, thereby stabilizing the slurry. The anionic polymer compound, which is used as the dispersing agent, may be any one selected from the group consisting of polymethacrylic acid, polyacrylic acid, ammonium polymethacrylate, ammonium polycarboxylate, carboxyl-acryl polymer, and a combination thereof. The reason for this is that the slurry of the present invention is based on water and the above polymer compound is soluble in water at normal temperature. In connection with this, it is preferable that the pH of the slurry be 6.5-13. Most preferably, the pH of the slurry is 7-11. Furthermore, it is suitable that the content of the added anionic polymer compound be 0.0001-10.0 wt % based on the polishing particles. It is preferable that the viscosity behavior of the stabilized ceria slurry be Newtonian behavior.
[0054] In connection with this, a mixture, which includes the dispersing agent and the additive, is milled using the high energy milling machine to reduce the particle size and to achieve dispersion. Next, the pulverized and dispersed slurry is transferred into a separate tank using a pump, and then dispersed again using an appropriate dispersing device to assure dispersion stability and prevent additional agglomeration and precipitation.
[0055] The dispersing agent may be added after the milling step, but, if necessary, it may be added in the course of mixing DI water with the ceria powder before the milling, or may be added during the milling step. Furthermore, the addition may be conducted using a combination thereof. Additionally, it is possible to obtain the slurry having increased dispersion stability by adding an appropriate amount of dispersing agent depending on the pH of the slurry, and a detailed description of this will be given later.
[0056] 4. Control of Solid Load (wt %) and Removal of Large Particles
[0057] As described above, after a dispersion stabilization process of the slurry is completed, the solid load (wt %) of the ceria slurry is controlled within a desired range, and the large particles which may cause scratches during CMP and may cause precipitation and agglomeration are removed by filtering. It is preferable that the concentration of solid load be 15 wt % or less. When a great volume of the large particles exists, the gravitational force is larger than the dispersion force caused by the repulsive force between the particles, and surface areas of the large particles are smaller than those of the fine particles, thus dispersibility of the large particles is less than that of the fine particles. For the above two reasons, agglomeration and precipitation frequently occur, making the slurry unstable. Therefore, it is necessary to remove the large particles. Furthermore, the removal of the large particles increases as the number of repetitions of filtering for removing the large particles increases.
[0058] 5. Aging of the Slurry
[0059] Stabilization of the slurry by aging is achieved by stirring the slurry in a tank for 24 hours so as to still further stabilize the slurry. This may be additionally conducted using the completed slurry, and may be omitted if necessary.
[0060] The polishing slurry may cause generation of micro-scratches, which fatally affect semiconductor devices during the fabrication of ultra highly integrated semiconductors of 0.13 μm or less due to the agglomeration of polishing particles. That is to say, in a polishing mechanism of the ceria polishing agent shown in FIG. 2 , a poly-crystal type of ceria particles are broken into single crystals, chemically reacted with oxide films deposited on a wafer, and then removed by a mechanical frictional force to a pad, thereby the polishing is achieved. In connection with this, as agglomeration of the polishing particles increases, the number of micro-scratches increases during breaking of the poly-crystals into single crystals and during breaking of agglomerated secondary particles into smaller secondary particles or primary particles. Therefore, it is necessary to minimize the agglomeration of polishing particles and to increase dispersion stability. In connection with this, a surface area per unit weight of ceria powder, an amount of dispersing agent added, and a stage at which the dispersing agent is added are important factors which are capable of largely affecting dispersion stability of the polishing particles.
[0061] dD15 or dD50 may be used as a useful standard for measuring the agglomeration of the slurry. That is to say, a particle size is measured using LA910 manufactured by Horiba, Inc. in Japan, and the results are used to calculate them. Their definitions are as follows.
dD1=D1 without sonication−D1 with sonication dD15=D15 without sonication−D15 with sonication dD50=D50 without sonication−D50 with sonication
[0065] In connection with this, each term is defined as described below.
[0066] D1 without sonication: a D1 particle size measured without exposure to ultrasonic waves
[0067] D1 with sonication: a D1 particle size measured with exposure to ultrasonic waves
[0068] D15 without sonication: a D15 particle size measured without exposure to ultrasonic waves
[0069] D15 with sonication: a D15 particle size measured with exposure to ultrasonic waves
[0070] D50 without sonication: a D50 particle size measured without exposure to ultrasonic waves D50 with sonication: a D50 particle size measured with exposure to ultrasonic waves
[0071] FIG. 3 illustrates definitions of D1, D15, and D50 depending on particle size.
[0072] As shown in FIG. 3 , D1, D15, and D50 correspond to an intermediate size and 50% of a total size distribution. D15 corresponds to 15% of the largest size, and D1 corresponds to 1% of the largest size.
[0073] In other words, where the particle size is measured using an LA910 model manufactured by Horiba, Inc., if the measurement is conducted with ultrasonic waves, the agglomerated slurry is redistributed, thus it is possible to measure the particle size in a dispersed state. On the other hand, if the measurement is carried out without ultrasonic waves, the agglomerated slurry is not redistributed, thus the particle size of the agglomerated slurry is measured. Hence, as an agglomerated portion of the slurry increases and as the dispersion stability of the slurry is reduced, variation in the particle size, that is, dD 1 , dD 115 , or dD50, increases.
[0074] Based on the above description, a detailed description will be given of the effect of calcination process conditions and addition conditions of the dispersing agent on the properties of ceria slurry.
[0075] [Change of Properties of Ceria Slurry Depending on the Calcination Process Conditions]
[0076] As in the following, the effect of the process conditions of the calcination process on properties of the ceria polishing particles will be analyzed. Particularly, a detailed description will be given of changes of dispersion stability and grain size, which are dependent on the surface area per unit weight of ceria powder depending on the calcination temperature and the holding time, and a change of micro-scratches corresponding to this.
[0077] After the surface area per unit weight is changed by changing the calcination conditions, the grain size, and dD1, dD15, or dD50 measured are as follows. In connection with this, the grain size is measured using an X-ray diffraction method, and dD1, dD15, or dD50 is measured using a light scattering method.
TABLE 1 Calcination Surface Grain dD1 dD15 dD50 conditions area (m 2 /g) size (nm) (nm) (nm) (nm) Sample 1 700° C. 1 H 72 17.1 745 303 152 Sample 2 700° C. 4 H 17 25.2 150 99 51 Sample 3 800° C. 4 H 3 35.5 75 39 23
[0078] As described above, if the surface area per unit weight of the polishing particle can be controlled depending on the calcination conditions, it is possible to control the agglomeration of the polishing particles, and this is closely connected with the number of micro-scratches. As the surface area per unit weight increases, the agglomeration increases, and the increased agglomeration increases the number of micro-scratches based on the above-mentioned polishing mechanism. Furthermore, since the porosity of the particles increases and the hardness of the polishing particles is reduced as the surface area increases, the removal rate is reduced. On the other hand, if the surface area is very small, the grain size increases, causing the generation of large grains and primary particles. Since the large particles have high hardness, the agglomeration may be reduced, but the number of micro-scratches increases due to the generation of large particles. Particularly, as described above, the number of micro-scratches increases as the hardness of the polishing particles increases when breaking the poly-crystals into single crystals and when breaking the agglomerated secondary particles into smaller secondary particles or primary particles. Thus, it is necessary to control the grain size of the polishing particles within a suitable range.
[0079] Accordingly, in the present invention, the surface area per unit weight and the grain size of ceria particles are controlled in order to produce a slurry which is capable of minimizing the generation of micro-scratches and maintaining a high removal rate. The surface area per unit weight of ceria particles is 1-100 m 2 /g, preferably 3-72 m 2 /g, and more preferably 5-25 m 2 /g. Furthermore, the grain size of the ceria particles is 15-40 nm, preferably 18-30 nm, and more preferably 20-25 nm.
[0080] The surface area per unit weight and the grain size of the polishing particle can be controlled depending on the calcination temperature and the holding time during the calcination process. The grain size increases and the surface area is reduced as the calcination temperature increases. As well, from FIGS. 4 and 5 which illustrate TEM pictures of the polishing particle calcined at 700° C. for 1 hour and the polishing particle calcined at 700° C. for 4 hours, respectively, it can be seen that the holding time is in proportion to the grain size.
[0081] Hence, in the present invention, in order to produce a slurry which is capable of minimizing the generation of micro-scratches and maintaining a high removal rate, the calcination temperature and the holding time are controlled as described below during the calcination process so that the surface area and the grain size are within the above-mentioned range. To minimize the generation of micro-scratches and maintain a suitable removal rate, the calcination temperature is set to 500-1000° C., preferably 600-800° C., and more preferably 650-750° C. Additionally, the calcination holding time is 10 min-10 hours, preferably 30 min-4 hours, and more preferably 1-2 hours.
[0082] [Change of Properties of Ceria Slurry Depending on the Addition Conditions of the Dispersing Agent]
[0083] As in the following, the effect of the amount of added dispersing agent and the stage at which it is added on properties of the ceria polishing particles will be analyzed. Particularly, a detailed description will be given of a change of dispersion stability, which is dependent on the optimum amount of dispersing agent added and the stage at which it is added depending on the pH, and a change of micro-scratches according to this.
[0084] First, the effect of the amount of added dispersing agent on the dispersion stability of the ceria slurry will be described.
[0085] To evaluate the degree of agglomeration depending on the amount of dispersing agent added, dD1, dD15, and dD50 of the polishing slurries produced using variable amounts of dispersing agents were measured, and the results are described in the following Table 2. In other words, sample 4 used 3.82 wt % of dispersing agent, sample 5 used 2.5 wt % of dispersing agent, and sample 6 used 1.6 wt % of dispersing agent. The pHs of all polishing slurries were 9.1, the dispersing agent was added before ceria powder was added to deionized water, and conditions other than the amount of added dispersing agent were the same.
TABLE 2 Dispersing Conductivity dD1 dD15 pH agent (wt %) (μs/cm) (nm) (nm) dD50 (nm) Sample 4 9.1 3.82 975 217 97 49 Sample 5 9.1 2.5 583 −5 −1 4 Sample 6 9.1 1.6 381 70 37 24
[0086] In the case of sample 4, even though the amount of dispersing agent is relatively large, agglomeration occurs in a large area without effective dispersion. The reason for this is that, since the amount of dispersing agent is too large, the particles are agglomerated due to a bridging action of the polymer dispersing agent. On the other hand, as for sample 6, the amount of dispersing agent is too small to cause satisfactory dispersion, thus agglomeration occurs in a large area. As described above, since dispersion stability is not increased in proportion to the amount of dispersing agent, the dispersing agent must be added in a suitable amount depending on various conditions, such as the pH and the surface area.
[0087] In the case of sample 5, the dispersing agent is added in a suitable amount, thus it is possible to minimize the agglomeration and obtain excellent dispersion stability.
[0088] The optimum amount of dispersing agent added is determined depending on the conductivity. As the conductivity increases, the amount of residual dispersing agent increases in a bulk solution, and this means that the dispersing agent is added in an amount that is still more than the optimum amount. In other words, when the conductivity is very high, a lot of dispersing agent is added, causing the agglomeration of particles due to the bridging action of excessive dispersing agent. Accordingly, the amount of added dispersing agent must be controlled depending on the conductivity.
[0089] In the present invention, it is preferable that the conductivity be 300-900 μs/cm. More preferably, the conductivity is 500-600 μs/cm. In connection with this, as the amount of dispersing agent added increases, the conductivity increases, and a decrease in the amount of added dispersing agent reduces the conductivity.
[0090] As shown in Table 2, if the amount of dispersing agent added is very small, the conductivity is very low and the agglomeration increases due to unsatisfactory dispersion. On the other hand, if the amount of dispersing agent added is very large, the conductivity is very high and the agglomeration increases due to the bridging action of polymer. Therefore, it is important to add the dispersing agent in a suitable amount, which is determined depending on various conditions, such as pH.
[0091] In order to evaluate the degree of agglomeration depending on pH to control the addition of the dispersing agent, dD1, dD15, and dD50 of the polishing slurries produced using variable amounts of dispersing agents in variable pHs were measured, and the results are described in the following Table 3. In other words, in sample 5, the pH of the slurry was 9.1, and in sample 7, the pH of the slurry was 8.4. The polishing agents were added in the same amount, 2.5 wt %, to the polishing slurries. Additionally, in sample 8, the pH of the slurry was 8.4, and 1.71 wt % of dispersing agent was added thereto. Other conditions of the polishing slurries were the same.
TABLE 3 Dispersing Conductivity dD1 dD15 pH agent (wt %) (μs/cm) (nm) (nm) dD50 (nm) Sample 5 9.1 2.5 583 −5 −1 4 Sample 7 8.4 2.5 1764 1313 529 149 Sample 8 8.4 1.71 578 18 12 5
[0092] In connection with this, in the case of sample 5, the amount of dispersing agent added was appropriately controlled depending on the pH to minimize the agglomeration. On the other hand, in the case of sample 7, the pH was lower than that of sample 2 and the dispersing agent was added in the same amount, thus the conductivity was rapidly increased, resulting in significantly increased agglomeration. The reason for this is that adsorption of the dispersing agent depends on the pH as shown in FIG. 6 . Referring to FIG. 6 , if the pH is 3, a particle surface has a positive (+) potential, and an anionic polymer dispersing agent has the shape of a twisted chain and strong adsorption strength to the particle surface. As the pH increases, the particle surface shows a negative (−) potential, thus the surface adsorption strength of the anionic dispersing agent is reduced and the twisted chain of polymer is untwisted. If the pH is as high as 10, the particle surface shows almost completely negative (−) potential, and the anionic polymer dispersing agent has a repulsive force to the particles, thus its chain expands, thereby stabilization is easily achieved in an aqueous solution due to strong forces between ions.
[0093] As described above, as the pH is reduced, the adsorption strength of the anionic polymer dispersing agent to the particle surface increases. Therefore, the bridging is excessively increased due to the strong adsorption strength of the dispersing agent, thereby the particles are rapidly agglomerated.
[0094] That is to say, by comparing sample 5 to sample 7, it can be seen that the conductivity is very high and the agglomeration increases when the pH is reduced and the adsorption strength of the dispersing agent to the particles increases. Hence, if the pH of the polishing slurry is low, the amount of dispersing agent added must be reduced.
[0095] In the case of sample 8, the pH was 8.4, as in sample 7, and the amount of dispersing agent added was controlled. That is to say, sample 7 used 2.5 wt % of dispersing agent and sample 8 used 1.71 wt % of dispersing agent, which is a smaller amount than the above amount. As described above, if the amount of dispersing agent added is reduced while the pH is maintained at a constant 8.4, the conductivity is reduced and reduction of the added amount compensates for an increase in the amount of dispersing agent adsorbed due to the reduction of the pH, thus it is possible to reduce the agglomeration and assure excellent dispersion stability.
[0096] As described above, where the amount of dispersing agent added is controlled, it is important to appropriately control the added amount in consideration of the pH of the slurry. The amount of dispersing agent depends on the conductivity, and when the amount is 500-600 μs/cm, dispersion stability is very high.
[0097] Furthermore, it is preferable that the amount of dispersing agent added be 2.2-3.0 wt % based on the polishing particles when the pH of the slurry is 8.7-9.5, 1.4-2.2 wt % based on the polishing particles when the pH of the slurry is 8.0-8.7, and 0.6-1.4 wt % based on the polishing particles when the pH of the slurry is 7.4-8.0.
[0098] Next, the effect of the stage at which the dispersing agent is added on the dispersion stability of the ceria slurry will be described.
[0099] In order to evaluate the degree of agglomeration depending on the stage at which the dispersing agent is added, dD1, dD15, and dD50 of polishing slurries which were produced under variable dispersing agent addition stage conditions were measured. As described above, dD1, dD15, and dD50 each mean variation in the particle size before and after forcible dispersion treatment using ultrasonic waves. In connection with this, ceria powders which were calcined under the same condition were employed to minimize the difference in size and surface area, and milling conditions were controlled so that particle sizes were constant in the course of producing the slurries.
[0100] Sample 9 was produced by adding a predetermined amount of dispersing agent before the milling process was conducted, and, in the case of sample 10, a predetermined amount of dispersing agent was added before the milling process was carried out and the dispersing agent was added at least one time during the milling process to produce sample 10. In connection with this, the amount of dispersing agent added and the number of additions before the milling process and during the milling process are controlled depending on the state of the slurry. Additionally, sample 11 was produced by adding the dispersing agent during the milling process, and sample 12 was produced by adding the dispersing agent after the milling process was finished. The variations of the particle sizes, that is, dD15 and dD50, which denote the degree of agglomeration of the polishing particles in the slurries produced under various conditions, were measured, and the results are described in Table 4.
TABLE 4 Stage at which dispersing agent is added dD1 (nm) dD50 (nm) dD15 (nm) Sample 9 Premixing 33 8 15 Sample 10 Premixing and 8 3 5 during milling Sample 11 During milling 157 25 51 Sample 12 After milling 760 152 290
[0101] As shown in Table 4, it can be seen that, in the case of sample 12, that is, where the dispersing agent is added after the milling process, the variation of the particle size is largest, thus the agglomeration of the polishing particles is most serious. Additionally, it can be seen that, like in samples 9 to 11, where the dispersing agent is added before the milling process and/or during the milling process, and where the dispersing agent is added a few times at early and middle steps of the milling process, the variation of the particle size is significantly reduced to 30 or less, thus the agglomeration of the polishing particles is minimized and dispersability is improved in comparison with sample 12.
[0102] The reason can be considered using a zeta potential as shown in FIG. 7 . FIG. 7 illustrates zeta potentials of the slurry before and after the dispersing agent is added. In connection with this, when the dispersing agent is added after milling, as in sample 12, the pH ranges from 5 to 8, and, after addition of the dispersing agent is finished, the pH ranges from 7 to 10. If the milling is carried out without the addition of the dispersing agent, the absolute value of the zeta potential is relatively low in comparison with the case where the milling is conducted with the dispersing agent added, thus pulverization is conducted while a lot of particles are agglomerated. In connection with this, even if the dispersing agent is added after the milling process is finished, it is adsorbed on surfaces of agglomerated secondary particles, thus agglomeration is not reduced. On the other hand, if the milling is conducted with the dispersing agent, dispersability is increased and the agglomeration is reduced due to a relatively high absolute value of a zeta potential. However, where the milling is carried out with the dispersing agent, the dispersing agent may be degraded due to high energy of a milling machine. Accordingly, if the dispersing agent is added in an excessive amount at an early step, dispersion stability is reduced. When the large-sized primary or secondary particles are pulverized into small-sized primary or secondary particles, new surfaces are additionally formed, thus it is possible to achieve effective dispersion by additionally adding the dispersing agent at the middle step so that it is adsorbed on the newly formed surfaces.
[0103] Therefore, in the present invention, it is preferable that the dispersing agent be added a few times before and after the milling step. That is to say, the dispersing agent is added at least one time before the milling step, and at least one time during the milling step. To achieve this, it is most preferable that the dispersing agent be added to deionized water and then mixed with the polishing particles, and the dispersing agent be further added to the mixture while it is milled. When the stage at which the dispersing agent is added is controlled as described above, variation (dD50) in the median size of the slurry particles according to the present invention is 30 or less. The variation of the particle size may have a negative value. Preferably, the variation of the particle size ranges from −10 to 10, and, most preferably, it ranges from −5 to 5.
[0104] As described above, it is possible to control the agglomeration of polishing particles depending on the amount of dispersing agent added and the stage at which it is added, and this is closely connected to the number of micro-scratches. Particularly, when CMP is carried out in practice, sonication is not conducted. Therefore, the particle size of the secondary particle may be changed by 200 nm or more according to dispersion stability during CMP, and the agglomeration of the polishing particles may cause the generation of micro-scratches during the CMP process.
[0105] In the following, the ceria powder and the slurry are produced under predetermined conditions through the above-mentioned method, and the properties of the polishing particles and the slurry, such as the particle size and the number of large particles of the slurry produced under the conditions, are analyzed.
[0106] First, analysis equipment is as follows.
[0107] 1) Surface Area: measured using BET Surface Area ASAP 2010 manufactured by Micromeritics Co. in the USA
2) Grain Size: measured using X'PERT Pro MRB manufactured by Philips company 3) Porosity: measured using Accupyc 1330 manufactured by Micromeritics Co. in the USA 4) pH & conductivity: measured using pH and conductivity meters manufactured by Orion, Inc. in the USA 5) Particle size distribution: measured using LA-910 manufactured by Horiba, Inc. in Japan 6) TEM: measured using JEM-2010 manufactured by JEOL Ltd. in Japan 7) XRD: measured using X'PERT Pro MRB manufactured by Philips company [Changes in Micro-Scratches Depending on Calcination Conditions]
[0114] First, the calcination conditions were controlled to evaluate changes of properties of slurry and micro-scratches depending on surface area per unit weight.
[0000] (1) Preparation of Ceria Powders 1 to 3
[0115] 25 kg of highly pure cerium carbonate was charged in a container by about 800 g, and calcined in a tunnel kiln at 700° C. for 1 hour to prepare ceria powder 1. Additionally, 25 kg of highly pure cerium carbonate was charged in a container by about 800 g, and calcined in a tunnel kiln at 700° C. for 4 hours to prepare ceria powder 2. Furthermore, 25 kg of highly pure cerium carbonate was charged in a container by about 800 g, and calcined in a tunnel kiln at 800° C. for 4 hours to prepare ceria powder 3. In all cases, the rate of temperature increase was 5° C./min during the calcination, cooling was spontaneously conducted, and gas flowed at a rate of 20 m 3 /hour in a direction that was opposite to a moving direction of a saggar in order to effectively remove CO 2 gas generated as a byproduct. The calcined ceria powders were analyzed using X-ray diffraction, and it was confirmed that highly pure ceria powders (cerium oxide) were produced.
[0116] (2) Preparation of Ceria Slurries 1 to 3
[0117] 10 kg of highly pure ceria powder 1, which was synthesized under the above-mentioned conditions, were mixed with 90 kg of deionized water, which included 1 wt % ammonium polymethacrylate as an anionic dispersing agent based on the ceria powder, for 1 hour or more in a high speed mixer so as to achieve sufficient wetting, and the mixture, that is, 10 wt % slurry, was milled using a pass-type milling process. Through the milling process, a particle size was controlled within a desired range and agglomerated particles in the slurry were dispersed. The ceria powders 2 and 3 were prepared through the procedure that was the same as the above-mentioned procedure.
[0118] (3) Comparison of the Ceria Slurries 1 to 3 and CMP Test Results
[0119] Objects were polished using the ceria slurries produced as described above, and, in this case, the removal rate, the number of scratches, and removal selectivity were evaluated, thereby the slurries were compared to each other. CMP polishing performance tests for the objects were carried out using the ceria slurries 1 to 3 produced as described above. 6EC, manufactured by Strasbaugh, Inc. in the USA was used as a CMP device. An 8″ wafer, on which PE-TEOS (plasma enhanced chemical vapor deposition TEOS oxide) was applied to form an oxide film on the entire surface thereof, and another 8″ wafer, on which Si 3 N 4 was applied to form a nitride film on the entire surface thereof, were used as an object wafer. Test conditions and consumption substances were as follows.
1) Pad: IC1000/SUBAIV (purchased from Rodel, Inc. in the USA) 2) Device for measuring a film thickness: Nano-Spec 180 (purchased from Nano-metrics, Inc. in the USA) 3) Table speed: 70 rpm 4) Spindle speed: 70 rpm 5) Down force: 4 psi 6) Back pressure: 0 psi 7) Amount of slurry supplied: 100 m l/min 8) Measurement of residual particles and scratches: measured using Surfscan SPI manufactured by KLA-Tencor, Inc. in the USA
[0128] Surfaces of the wafers, on which the oxide film (PE-TEOS) and the nitride film (Si 3 N 4 ) were formed, were polished using the slurries 1 to 3 which were produced under the conditions for 1 min. The removal rate was determined from a thickness change of the polished film, and the micro-scratches were measured using Surfscan SP1. Particularly, in order to apparently evaluate changes of dispersion stability and the degree of agglomeration depending on a change of the surface area before the CMP test was carried out, the slurries were mixed with deionized water without a re-dispersion process after aging was conducted for 1 month or more before the test was conducted. Polishing performance for the slurries was tested in such a way that polishing characteristics were measured after a blank wafer was polished three times or more.
TABLE 5 ? Removal Removal Oxide film Surface Removal rate of ratio of residual area per Grain rate of nitride oxide: particles unit size oxide film film nitride WIWNU (>0.20 Scratches weight (nm) (Å/min) (Å/min) (selectivity) (%) μm, #) (#) Slurry 1 72 17.1 2332 49 47.6 1.0 440 3 Slurry 2 17 25.2 2521 49 51.4 1.0 150 1 Slurry 3 5 35.5 2680 50 53.6 1.0 210 2 Comp. 250 13 2005 49 40.9 1.1 780 9 Exm. 1 Prior art
[0129] The CMP test was conducted using the ceria slurries 1 to 3, which were produced so as to have different surface areas of the ceria powders depending on calcination and milling conditions as described above, under the same CMP conditions, and the results are described in Table 5. The ceria slurries 1 to 3 all have fair removal rate and removal selectivity (ratio of oxide film removal to nitride film removal), and also excellent within-wafer-nonuniformity (WIWNU) which indicates removal uniformity of the polished wafer during the polishing process. Furthermore, in all of the ceria slurries 1 to 3, the numbers of oxide film residual particles and scratches are significantly reduced iri comparison with slurry according to a prior art. Particularly, with respect to the change of micro-scratches depending on the change of the surface areas of the ceria powders, as the surface area per unit weight increases, dispersion stability is reduced and the agglomeration becomes serious, thus the numbers of oxide film residual particles and micro-scratches are increased. However, if the surface area per unit weight of the polishing particles is reduced, crystallinity is increased to increase the removal rate of oxide film. If large particles are generated because of excessive reduction of the surface area, as in the slurry 3, the number of micro-scratches increases.
[0130] [Change in Micro-Scratches Depending on the Addition Conditions of the Dispersing Agent]
[0131] First, changes of properties of slurry and micro-scratches, which were dependent on the amount of dispersing agent added, were examined.
[0000] (1) Preparation of Ceria Powders 4 to 8
[0132] 25 kg of highly pure cerium carbonate was charged in a container by about 800 g, and calcined in a tunnel kiln at 700° C. for 4 hours to prepare ceria powders 4 to 8. During all of the calcination processes, calcination conditions other than calcination temperature and holding time were identical to the above-mentioned conditions. The calcined ceria powders were analyzed by X-ray diffraction, and it was confirmed that highly pure ceria powders (cerium oxide) were produced.
[0133] (2) Preparation of Ceria Slurries 4 to 8
[0134] 10 kg of highly pure ceria powder 4, which were synthesized under the above-mentioned conditions, were mixed with 90 kg of deionized water, which included 1 wt % ammonium polymethacrylate as an anionic dispersing agent based on the ceria powder, for 1 hour or more in a high speed mixer so as to achieve sufficient wetting, and the mixture, that is, 10 wt % slurry, was milled using a pass-type milling process. Through the milling process, particle size was controlled within a desired range and agglomerated particles in the slurry were dispersed. The ceria slurries 5 and 8 were produced through the same procedure as was the ceria slurry 4 except that the amounts of dispersing agent added were 2.5 wt % and 1.6 wt %. In the case of the ceria slurries 4 to 6, the pH was titrated to 9.1. The ceria slurry 7 was produced through the same procedure as was the ceria slurry 5 except that the pH was titrated to 8.4 using acetic acid. Furthermore, the ceria slurry 8 was produced through the same procedure as was the ceria slurry 7 except that the amount of dispersing agent added was controlled to 1.71 wt %.
[0135] (3) Comparison of the Ceria Slurries 4 to 8 and CMP Test Results
[0136] Objects were polished using the ceria slurries produced as described above, and, the removal rate, the number of scratches, and removal selectivity were evaluated, thereby the slurries were compared to each other. CMP polishing performance tests for the objects were carried out using the ceria slurries 4 to 8 produced as described above. In connection with this, a CMP device, an object wafer, test conditions, and consumption substances were the same as those of the above evaluation.
[0137] The pH, conductivity, and dD50, dD15, and dD1 values for the slurries were the same as those of Table 2 or 3. That is to say, the ceria slurry 4 was produced using sample 4, the ceria slurry 5 was produced using sample 5, the ceria slurry 6 was produced using sample 6, the ceria slurry 7 was produced using sample 7, and the ceria slurry 8 was produced using sample 8.
TABLE 6 Oxide Removal Removal film Removal rate of ratio of residual rate of nitride oxide: particles Disp. Cond. oxide film film nitride WIWNU (>0.20 Scratches pH (wt %) (μm/cm) (Å/min) (Å/min) (selectivity) (%) μm, #) (#) Slurry 4 9.1 3.82 975 2632 49 53.7 1.0 460 4 Slurry 5 9.1 2.5 583 2521 49 51.4 1.0 150 1 Slurry 6 9.1 1.6 381 2580 50 51.6 1.0 310 2 Slurry 7 8.4 2.5 1764 2720 52 52.3 1.0 2350 32 Slurry 8 8.4 1.71 578 2570 50 51.4 1.0 180 1 Disp.: Dispersing agent Cond.: Conductivity
[0138] The CMP test was conducted using the ceria slurries 4 to 8, which were produced so as to have different amounts of dispersing agent added depending on the pH as described above, under the same CMP conditions, and the results are described in Table 6. The slurries 4 to 8 all have fair removal rate and removal selectivity (ratio of oxide film removal to nitride film removal), and also excellent within-wafer-nonuniformity (WIWNU) which indicates removal uniformity of the polished wafer during the polishing process. The degree of agglomeration or dispersion of the polishing particles and the number of micro-scratches are changed depending on the amount of dispersing agent added. That is to say, since the slurry 4 contains a great amount of dispersing agent, the agglomeration occurs in a large area. The slurry 6 contains a very small amount of dispersing agent, thus the agglomeration occurs in a large area without dispersion, thereby the formed large particles generate micro-scratches. As well, in the case of the slurry 7, since the amount of dispersing agent added is not appropriately controlled as the pH is reduced, the dispersing agent is added in an excessive amount to induce the agglomeration of the particles, thereby the micro-scratches are significantly increased.
[0139] As described above, the reason for the agglomeration of the slurry is that, since the amount of dispersing agent added is less than an optimum amount, dispersion efficiency is reduced, or that, since the amount of dispersing agent added is excessively large, agglomeration occurs due to bridging. Accordingly, the dispersing agent must be added in an appropriate amount in consideration of the pH of the slurry.
[0140] The amount of dispersing agent suitable for addition must decrease as the pH of the slurry is reduced. It is preferable that the amount of dispersing agent added be 2.2-3.0 wt % based on the polishing particles when the pH of the slurry is 8.7-9.5, 1.4-2.2 wt % based on the polishing particles when the pH of the slurry is 8.0-8.7, and 0.6-1.4 wt % based on the polishing particles when the pH of the slurry is 7.4-8.0.
[0141] The preferable amount of dispersing agent is obtained when the conductivity is 300-900 μs/cm, and more preferably, it is obtained when the conductivity is 500-600 μs/cm.
[0142] Next, changes in the properties of slurry and micro-scratches, which were dependent on a stage at which the dispersing agent was added, were examined.
[0143] (1) Preparation of ceria powders 9 to 11
[0144] 25 kg of highly pure cerium carbonate was charged in a container by about 800 g, and calcined in a tunnel kiln at 700° C. for 4 hours to prepare ceria powders 9 to 11. During all of the calcination processes, calcination conditions other than calcination temperature and holding time were identical to the above-mentioned conditions. The calcined ceria powders were analyzed by X-ray diffraction, and it was confirmed that highly pure ceria powders (cerium oxide) were produced.
[0145] (2) Preparation of Ceria Slurries 9 to 11
[0146] The ceria slurry 9 was produced using 10 kg of highly pure ceria powder 9, which was synthesized under the above-mentioned conditions. First, 1 wt % ammonium polymethacrylate as an anionic dispersing agent based on the ceria powder was added to 90 kg of deionized water, and sufficiently mixed in a high speed mixer. Subsequently, 10 kg of highly pure ceria powder 9 were added to deionized water which was uniformly mixed with the anionic dispersing agent, and mixing was conducted in the high speed mixer for 1 hour or more so as to achieve sufficient wetting. Next, the mixture, that is, 10 wt % slurry, was milled using a pass-type milling process. Through the milling process, particle size was controlled within a desired range and agglomerated particles in the slurry were dispersed. Subsequently, filtering was conducted to remove the large particles, thereby the ceria slurry 9 was created.
[0147] The ceria slurry 10 was produced using 10 kg of ceria powder 10. First, 0.5 wt % ammonium polymethacrylate as an anionic dispersing agent based on the ceria powder was added to 90 kg of deionized water, and sufficiently mixed in a high speed mixer. Subsequently, 10 kg of highly pure ceria powder 10 were added to deionized water which was uniformly mixed with the anionic dispersing agent, and mixing was conducted in the high speed mixer for 1 hour or more so as to achieve sufficient wetting. Next, the mixture, that is, 10 wt % slurry, was milled using a pass-type milling process. During the milling process, 0.5 wt % ammonium polymethacrylate as the anionic dispersing agent based on the ceria powder were further added thereto, and mixing was conducted. Through the milling process, a particle size was controlled within a desired range and agglomerated particles in the slurry were dispersed. Subsequently, filtering was conducted to remove large particles, thereby ceria slurry 10 was created.
[0148] Furthermore, 10 kg of ceria powder 11 and 90 kg of deionized water were mixed in a high speed mixer for 1 hour or more so as to achieve sufficient wetting, and the mixture, that is, 10 wt % slurry, was milled using a pass-type milling process. During the milling process, 1 wt % ammonium polymethacrylate as the anionic dispersing agent based on the ceria powder was further added thereto, and mixing was conducted. Subsequently, the milling was further carried out so that particle size was controlled within a desired range, and filtering was conducted to create the ceria slurry 11.
[0149] Finally, in the case of the sample of comparative example, 10 kg of ceria powder, which was synthesized under the above-mentioned conditions, and 90 kg of deionized water were mixed in a high speed mixer for 1 hour or more so as to achieve sufficient wetting, and the mixture, that is, 10 wt % slurry, was milled using a pass-type milling process. Through the milling process, particle size was controlled within a desired range and agglomerated particles in the slurry were dispersed. Subsequently, 1 wt % ammonium polymethacrylate as the anionic dispersing agent based on the ceria powder was further added thereto, and dispersion was conducted by mixing for 2 hours or more in consideration of adsorption thereof. Next, filtering was conducted to prepare the sample of comparative example 2.
[0150] The present invention is not limited to the above-mentioned time and amount, but the stage at which the dispersing agent is added and the amount of dispersing agent added may be changed. As described above, the anionic dispersing agent is added to deionized water, and the ceria powder is then mixed with deionized water. The resulting mixture is milled and filtered to produce the slurry. Furthermore, in the present invention, the slurry may be created through the following procedure. After the ceria powder is mixed with deionized water to achieve sufficient wetting, the anionic dispersing agent is added thereto, and the resulting mixture is milled/dispersed using a milling machine and filtered to remove large particles, thereby the slurry is created. Alternatively, the anionic dispersing agent and the ceria powder may be added to deionized water, mixed, milled, and filtered to produce slurry.
[0151] Meanwhile, in the present invention, the dispersing agent is added using various methods before the milling as described above, and deionized water, which is mixed with the dispersing agent and the ceria crude powder, is milled. In connection with this, the anionic dispersing agent is further added at least one time during the milling, the milling/dispersion are carried out, and filtering is conducted, thereby the slurry is created. Alternatively, in the present invention, the dispersing agent may be further added after the milling is finished.
[0152] Where the dispersing agent is added a few times as described above, it is possible to control the amount of dispersing agent added per time, which is dependent on the number of additions of the dispersing agent. For example, the dispersing agent may be added in the amount of 0.0001-10 wt % based on the polishing particles in such a way that the dispersing agent is added in deionized water in the amount of 100-50% based on the total amount of dispersing agent, and that the dispersing agent is added in the course of milling the mixture in the amount of 50% or less based on the total amount of dispersing agent.
[0153] Meanwhile, a predetermined additive may be added after the milling.
[0154] (3) Comparison of the Ceria Slurries 9 to 11 and CMP test results
[0155] Objects were polished using the ceria slurries produced as described above, and, in this case, the removal rate, the number of scratches, and removal selectivity were evaluated, thereby the slurries were compared to each other. CMP polishing performance tests for the objects were carried out using the ceria slurries 9 to 11 produced as described above. In connection with this, a CMP device, an object wafer, test conditions, and consumption substances were the same as those of the above evaluation.
TABLE 7 Oxide Stage at Removal film which Removal Removal ratio of residual dispersing rate of rate of oxide: particles agent is oxide film nitride film nitride WIWNU (>0.20 Scratches added dD50 (Å/min) (Å/min) (selectivity) (%) μm, #) (#) Slurry Before 8 2521 49 51.4 1.0 150 1 9 milling Slurry Before 3 2492 50 49.8 1.0 50 0 10 milling and during milling Slurry During 25 2462 49 50.2 1.0 130 2 11 milling Comp. After 157 2521 50 50.4 1.0 680 10 Exm. 2 milling
[0156] The CMP test was conducted using the ceria slurries 9 to 11, which were produced so as to have different times for adding the dispersing agent as described above, under the same CMP conditions, and the results are described in Table 7. The slurries all have fair removal rate and removal selectivity (ratio of oxide film removal to nitride film removal), and also excellent within-wafer-nonuniformity (WIWNU) which indicates removal uniformity of the polished wafer during the polishing process. However, in view of the numbers of micro-scratches and oxide film residual particles which are still important in a highly integrated semiconductor process, the ceria slurries 9 to 11 are very different from that of comparative example 2. That is to say, in the case of the ceria slurries 9 to 11, in which the dispersing agent is added before and/or during the milling process, agglomeration of the slurry is reduced and dispersion stability is improved, thus the numbers of micro-scratches and oxide film residual particles are significantly reduced in comparison with comparative example 2 in which the dispersing agent is added after milling. The reason is that, in the case of the ceria slurries 9 to 11, when novel surfaces are formed, the dispersing agent is relatively nicely adsorbed on the newly formed surfaces, but, in the case of comparative example 2, the dispersing agent is adsorbed only on surfaces of agglomerated particles in the slurry and also interposed between the agglomerated particles without adsorption. Therefore, it is possible to minimize the agglomeration of ceria slurry by changing the stage at which the dispersing agent is added, the method of adding it, and the method of using dispersing devices.
[0157] As described above, in the present invention, the amount of dispersing agent added is controlled and the stage at which the dispersing agent is added is changed depending on the predetermined pH condition in order to control dispersion stability of the ceria slurry, thereby it is possible to easily produce the slurry which is capable of minimizing micro-scratches and maintaining a high removal rate and selectivity.
[0158] A detailed description will be given below of a method of polishing a substrate using the above-mentioned slurry.
[0159] In the method of polishing the substrate according to the present invention, a predetermined substrate is polished using a polishing slurry in which the agglomeration of polishing particles is minimized and dispersion stability is improved by controlling calcination process conditions, the amount of dispersing agent added, and the stage at which it is added.
[0160] Preferably, the method comprises preparing the substrate on which a polishing layer and a polishing stopper layer are formed, and polishing the polishing layer using the polishing slurry in which the agglomeration of the polishing particles is minimized and dispersion stability is improved by controlling the calcination process conditions, the amount of dispersing agent added, and the stage at which it is added. The polishing slurry consists of an oxide-based material layer, and the polishing stopper layer consists of a nitride-based material layer.
[0161] As described above, in the present invention, it is possible to produce a slurry having excellent physical properties which are essential in a polishing agent for an STI CMP process during the fabrication of a semiconductor. Particularly, it is possible to decrease scratches and residual particles which cause fatal defects in a device after CMP.
[0162] Furthermore, in the present invention, it is possible to develop a slurry which is capable of reducing the number of micro-scratches causing defects in a device and maintaining a high removal rate during a CMP process by controlling the surface area per unit weight of polishing particles and the addition amount and stage of a dispersing agent, depending on calcination process conditions, so as to improve the dispersion stability.
[0163] As well, in the present invention, it is possible to produce a slurry which has excellent physical properties essentially required as a polishing agent for STI CMP. Accordingly, when the slurry is used as the polishing agent for STI CMP, it can be applied to various patterns required in the course of producing ultra highly integrated semiconductors, and thus excellent removal rate, removal selectivity, and within-wafer-nonuniformity (WIWNU), which indicates removal uniformity, as well as minimal occurrence of micro-scratches, can be assured. | Disclosed is a polishing slurry, particularly, a slurry for chemical mechanical polishing, which is used in a chemical mechanical polishing process for flattening a semiconductor laminate. More particularly, the present invention provides a method of producing a slurry which has high removal selectivity to a nitride layer used as a barrier film in a shallow trench isolation CMP process needed to fabricate ultra highly integrated semiconductors of 256 mega D-RAM or more (Design rule of 0.13 μm or less) and which decreases the occurrence of scratches on a flattened surface, and a method of polishing a substrate using the same. | 73,147 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. application Ser. No. 10/970,290, filed Oct. 21, 2004, and is based upon and claims the benefit of priority from prior Japanese Patent Application No. 2003-363925, filed Oct. 23, 2003, the entire contents of each of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an electronic device having a hinge that joins a body and a display. More particularly, the present invention is concerned with the electronic device in which an outer space in the hinge is effectively utilized.
[0004] 2. Description of the Related Art
[0005] Notebook computers have been known for some time as an electronic device with a body and a display which can freely be opened away from the body and closed onto the body.
[0006] In the electronic device, for example, as disclosed in Patent Document 1, a power switch is flush with a keyboard included in the body. Moreover, in the electronic device disclosed in Patent Document 2, the power switch is juxtaposed with other operation switches on the lateral side of the body. Moreover, since a motherboard is incorporated in the body, connectors allowing linkage with external equipment or a communication line are disposed on the lateral side or rear side of the body.
[Patent Document 1] Japanese Unexamined Patent Publication No. 2002-108505 [Patent Document 2] Japanese Unexamined Patent Publication No. 2002-7048
[0009] In recent years, the electronic device has become more and more compact. There is difficulty in preserving a space, in which components are disposed, in a body and a display alike. Moreover, for realization of thinner equipment, it proves effective to limit the number of components to be incorporated in the body. The present inventor et al. have given attention to a space created at an outer end of the shaft of a hinge other than the body and the display. A power switch or a connector that are conventionally included in the body is disposed in the space in efforts to thin the body.
SUMMARY OF THE INVENTION
[0010] In one aspect, an electronic device in accordance with the present invention comprises a body, a display, and a hinge that joins the body and display so that they can freely be opened or closed. A power switch is formed at an edge of the shaft of the hinge.
[0011] In another aspect, the electronic device in accordance with the present invention comprises a body, a display, and a hinge that joins the body and display so that they can be freely opened or closed. A port of a connector opens at an end of the shaft of the hinge.
[0012] As mentioned above, since the power switch or connector is disposed in a space at an end of the shaft of a hinge which has been left unused as a so-called dead space in the past, the freedom in disposing components in the body or display is expanded accordingly. By devising the layout of the components, thinning of the body and display is facilitated.
[0013] According to the electronic device in which the present invention is implemented, a power switch is disposed at an end of the shaft of a hinge. A space in the electronic device that has not been used at all in the past can be utilized effectively. The number of components to be incorporated in the body can be reduced, and the freedom in laying out components is expanded accordingly.
[0014] Consequently, the body can be further thinned.
[0015] Moreover, since the power switch is disposed away from a keyboard and other operation buttons, the power switch can be prevented from being pressed by mistake and accurately manipulated.
[0016] Moreover, according to the electronic device in which the present invention is implemented, a port of a connector opens at an end of the shaft of a hinge. A space present in electronic device that is conventionally not used at all can be utilized effectively. The number of components to be incorporated in a body can be reduced. The freedom in laying out components is expanded accordingly.
[0017] Consequently, the body can be further thinned.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a perspective view of an electronic device according to an embodiment of the invention in an opened state;
[0019] FIG. 2 is a perspective view of the electronic device in a closed state;
[0020] FIG. 3 is a plan view of the inside of a lower section 27 of a case 26 of the electronic device;
[0021] FIG. 4 is a side view of the lower section 27 as seen along the arrows [ 4 ] and [ 4 ] of FIG. 3 ;
[0022] FIG. 5 is a plan view of the built-in components disposed in the case 26 ;
[0023] FIG. 6 is a plan view of one surface of a motherboard to be fitted into the case 26 ;
[0024] FIG. 7 shows the other surface of the motherboard shown in FIG. 6 ;
[0025] FIG. 8 is a plan view of connectors and a flexible wiring board provided in the case 26 ;
[0026] FIG. 9 is a front view of the connectors and the flexible wiring board of FIG. 8 ;
[0027] FIG. 10 is an enlarged front view of the connectors shown in FIGS. 8 and 9 ;
[0028] FIG. 11 is a plan view of a keyboard fitted into the case 26 ;
[0029] FIG. 12 is a front view of the keyboard;
[0030] FIG. 13 is a rear view of the keyboard;
[0031] FIG. 14 is a left-side view of the keyboard;
[0032] FIG. 15 is a right-side view of the keyboard;
[0033] FIG. 16 is a back side view of the keyboard;
[0034] FIG. 17 is a plan view of the inside of the upper section 28 of the case 26 ;
[0035] FIG. 18 is a schematic cross section of the inside of the case 26 where heat-generating components are placed;
[0036] FIG. 19 is a plan view of the inside of a case 22 ;
[0037] FIG. 20 is a side view of the case 22 as seen along the arrows [ 20 ] and [ 20 ] in FIG. 19 ;
[0038] FIG. 21 is a plan view of a liquid crystal panel and an inverter circuit board fitted in the inside of the case 22 ;
[0039] FIG. 22 is an enlarged plan view of a principal part of the liquid crystal panel being housed in the case 22 ;
[0040] FIG. 23 is an enlarged view of one of the two constituent parts of hinges formed at the back of the case 22 ;
[0041] FIG. 24 is an enlarged view of the other constituent part of the hinges formed at the back of the case 22 ;
[0042] FIG. 25 is a schematic diagram showing a construction of a power switch installed in the constituent part of the hinge shown in FIG. 23 ;
[0043] FIGS. 26A and 26B are schematic cross sections of the laminated structure of the case 22 of the electronic device according to the present embodiment;
[0044] FIGS. 27A and 27B show the pieces of conductor foil being stuck onto the laminated layer of FIGS. 26A and 26B ;
[0045] FIG. 28 shows a resin material being stuck onto edge portions of the laminated layers shown in FIG. 26 ;
[0046] FIG. 29 is an enlarged view of the rear portion of the electronic device in an opened state according to the present embodiment; and
[0047] FIG. 30 is an enlarged view of the front edge portion of the electronic device in a closed state according to the present embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0048] Now, an embodiment of an electronic device in accordance with the present invention will be described below. The embodiment is a notebook computer.
[0049] FIGS. 1 and 2 show the outer appearances of the electronic device 1 of the present embodiment. The electronic device 1 comprises a body 3 , a display 5 , and two hinges “h” which fasten the display 5 to the body 3 .
[0050] The display 5 pivots on the hinges “h” to open away from the body 3 and close onto the body 3 . In FIG. 1 , the display 5 is opened away from the body 3 . In FIG. 2 , the display 5 is closed onto the body 3 .
[0051] The body 3 has a case 26 . Disposed in the case 26 as shown in FIG. 5 are a keyboard 11 , a motherboard 30 , a hard-disk drive 32 , a PC card slot 34 , and connectors 40 a - d.
[0052] The keyboard 11 is an input unit of the electronic device 1 . The motherboard 30 is the substantially main functional component of the electronic device 1 and receives signals inputted through the keyboard 11 and makes various kinds of processing such as arithmetic processing, control processing, image processing, and processing to output signals to the display 5 .
[0053] The motherboard 30 serves as a control circuit board to control individual components such as the keyboard 11 and the display 5 , too.
[0054] The case 26 comprises an upper section 28 and a lower section 27 . FIG. 3 is a plan view of the inside of the lower section 27 .
[0055] FIG. 4 is a side view of the lower section 27 as seen along the arrows [ 4 ] and [ 4 ] of FIG. 3 .
[0056] The lower section 27 looks like a flat box and has an almost rectangular bottom plate 27 a , right and left side plates 27 b and 27 d , and a back plate 27 c . As shown in FIGS. 3 and 4 , the side and back plates 27 b - d are erected on the three sides of the bottom plate 27 a.
[0057] The back plate 27 c is erected on the back side of the bottom plate 27 a and has outward-protruding constituent parts 42 a and 42 b of the hinges “h” as shown in FIGS. 3 and 4 .
[0058] As shown in FIGS. 3 and 4 , there are cuts 43 a - d in the left side plate 27 b for the connectors 40 a - d and a cut 43 e in the right side plate 27 d for the PC card slot 34 .
[0059] The inside of the bottom plate 27 a is provided with a resin mold 45 , which is raised from the inside surface of the bottom plate 27 a to reinforce the lower section 27 against bending and twisting.
[0060] A heat-transmitting sheet 47 is stuck on the inside surface of the bottom plate 27 a . The heat-transmitting sheet 47 is positioned near to the center between the right and left sides of the bottom plate 27 a and one-sided toward the back side of the bottom plate 27 a.
[0061] The heat-transmitting sheet 47 is, for example, a graphite sheet 0.1 to 1.0 mm thick. Because the heat-transmitting sheet 47 is positioned in an area where the mold 45 does not exist, the heat-transmitting sheet 47 does not float, but is closely stuck onto the inside of the bottom plate 27 a ; accordingly, the heat from heat-generating components to be described later is diffused effectively through the lower section 27 .
[0062] An elastic sheet 48 is laid between the heat-transmitting sheet 47 and the bottom plate 27 a . The elastic sheet 48 is rectangular and larger than the heat-generating components. The elastic sheet 48 is positioned substantially in the middle of the lateral width of the lower section 27 within about a half of the bottom 27 a near the wall portion 27 c.
[0063] To be specific, the elastic sheet 48 is 0.5-3.0 mm thick and made of Poron (of Rogers Inoac Corporation) which is high-density polyurethane foam whose cells are fine and uniform.
[0064] An insulating sheet 49 is overlaid on the heat-transmitting sheet 47 ; accordingly, short circuits between the heat-transmitting sheet 47 , which is made of graphite and conductive, and the motherboard, which is put on the heat-transmitting sheet 47 , are prevented.
[0065] The insulating sheet 49 is, for example, a transparent thin film of polyphenylene sulfide. It is as thin as, for example, 0.05-0.3 mm; therefore, it does not prevent heat transmission from the heat-generating components to the heat-transmitting sheet 47 .
[0066] The lower section 27 is made of CFRP (carbon fiber reinforced plastics). To be specific, the CFRP consists of six layers 51 a , 51 b , 52 a , 52 b , 53 a , and 53 b as shown in FIG. 26 .
[0067] As shown in FIG. 26A , the six layers 51 a , 51 b , 52 a , 52 b , 53 a , and 53 b are pressed together.
[0068] Each layer is made of long carbon fibers solidified by epoxy resin. All the fibers of each layer are put side by side in one and the same direction.
[0069] To be specific, the carbon fibers of the innermost layers 51 a and 51 b are laid in the longitudinal direction of the electronic device 1 . Accordingly, the carbon fibers of the layer 51 a are parallel to those of the layer 51 b.
[0070] The carbon fibers of the intermediate layers 52 a and 52 b are laid in the lateral direction of the electronic device 1 .
[0071] The carbon fibers of the outermost layers 53 a and 53 b are laid in the direction at angles of 45° with the longitudinal and lateral directions of the electronic device 1 . Accordingly, the carbon fibers of the layer 53 a are parallel to those of the layer 53 b.
[0072] With the above laminated structure, the thin lower section 27 has sufficient strength. As the lower section 27 is thin, the electronic device 1 is also thin, which is an advantage for portable electronic devices in particular.
[0073] As shown in FIG. 28 , an insulating layer 56 is formed on the inside surface of the bottom plate 27 a . The insulating layer 56 is made of, for example, nylon (a trade name of Du Pont).
[0074] The insulating layer 56 prevents short circuits between the lower section 27 , which is made of CFRP (carbon fiber reinforced plastics) containing conductive carbon fibers, and the motherboard 30 fitted in the lower section 27 .
[0075] When the insulating layer 56 made of nylon is heated, it softens and becomes adhesive. By making use of the adhesiveness of the insulating layer 56 , the mold 45 is stuck and fixed to the insulating layer 56 . The mold 45 has bosses with threaded holes, etc.
[0076] As shown in FIG. 28 , the front edge of the lower section 27 is provided with a resin cover 45 a . By making use of the adhesiveness of the insulating layer 56 , the cover 45 a is stuck onto the insulating layer 56 to cover the front edge of the lower section 27 . Thus, loose ends of carbon fibers, if any, at the front edge of the lower section 27 are covered up.
[0077] As shown in FIG. 3 , because the resin cover 45 a extends along the front edge of the lower section 27 , it serves as a beam, too, reinforcing the lower section 27 against bending and twisting.
[0078] The resin cover 45 a and the mold 45 are made of nylon as well as the insulating layer 56 ; accordingly, the cover 45 a and the mold 45 are stuck on the insulating layer 56 sufficiently. As shown in FIG. 28 , a groove 54 is made in the surface of the resin cover 45 a which comes in contact with the insulating layer 56 . When the insulating layer 56 is heated and softened and the cover 45 a is stuck on the insulating layer 56 , surplus softened, adhesive nylon enters into the groove 54 .
[0079] Thus, the surplus softened, adhesive nylon is prevented from leaking out through the joint between the lower section 27 and the cover 45 a . If the surplus softened, adhesive nylon leaks out, the appearance of the electronic device 1 is spoiled.
[0080] Because the right and left side plates 27 b and 27 d are erected on the right and left sides, respectively, and the back plate 27 c is erected on the back side of the bottom plate 27 a , these plates 27 b , 27 c , and 27 d play the role of the cover 45 a.
[0081] Now, the motherboard to be fitted in the lower section 27 will be described below by referring to FIGS. 6 and 7 . FIG. 6 shows the upper surface of the motherboard 30 ; FIG. 7 , the lower surface. A central processor 58 is mounted on the upper surface. An image processor 60 and a plurality of semiconductor memories 62 are mounted on the lower surface. Although not shown in FIGS. 6 and 7 , many other components are mounted on both the surfaces of the motherboard 30 .
[0082] The central processor 58 and the image processor 60 are semiconductors and generate heat when they function. The central processor 58 and the image processor 60 are so positioned that they do not overlap with each other.
[0083] The motherboard 30 comprises a multi-layer printed circuit board and the central processor 58 , the image processor 60 , the semiconductor memories 62 , and other components (not shown) mounted on both the surfaces of a multi-layer printed circuit board and is the substantial body of the electronic device 1 in terms of functions of the electronic device 1 .
[0084] The multi-layer printed circuit board is made by the buildup method as follows. A two-layer printed circuit board (hereinafter “intermediate two-layer printed circuit board”) is laid on each of the upper and lower surfaces of an innermost two-layer printed circuit board. A single-layer printed circuit board is laid on the upper surface of the upper intermediate two-layer printed circuit board; a single-layer printed circuit board, on the lower surface of the lower intermediate two-layer printed circuit board. A single-layer printed circuit board is laid on the upper surface of the upper single-layer printed circuit board; a single-layer printed circuit board, on the lower surface of the lower single-layer printed circuit board. Thus, a ten-layer printed circuit board is made. The buildup method enables us to do wiring efficiently and high-density mounting of parts.
[0085] The connectors 40 a - d shown in FIGS. 8-10 are also fitted in the lower section 27 . The connectors 40 a - d are connected to the motherboard 30 through a flexible wiring board 67 . Namely, the connectors 40 a - d are connected to wires at one end of the flexible wiring board 67 , and the other end 67 a of the flexible wiring board 67 is inserted into a connector mounted on the motherboard 30 .
[0086] As shown in FIG. 10 , the connector 40 b is provided two flanges 64 protruding from the right and left shorter sides of its socket. By fixing the flanges 64 to the left side plate 27 b by using, for example, screws, the connector 40 b can be fixed to the left side plate 27 b . The connector 40 c has the same flanges 64 as the connector 40 b.
[0087] The keyboard 11 shown in FIGS. 11-16 is fitted to the lower section 27 . FIG. 11 is a plan view of the keyboard 11 . FIGS. 12 and 13 are front and rear views, respectively, of the keyboard 11 . FIGS. 14 and 15 are left and right side views, respectively, of the keyboard 11 . FIG. 16 is a bottom view of the keyboard 11 .
[0088] The keyboard 11 comprises a case 37 , input keys 13 , a pointing device 14 called “track point,” and a cover 36 .
[0089] The case 37 is made of, for example, magnesium and in the shape of a flat box, having a key-arrangement area and side plates erected around the key-arrangement area.
[0090] The key-arrangement area is in the shape of an almost rectangular flat plate and the side plates are formed, as a single piece, at the right, left, top, and bottom sides of the key-arrangement area.
[0091] As described above, the case 37 is not a flat plate, but in the shape of a flat box, having the side plates; accordingly, its rigidity is high. When a user presses keys 13 , the case 37 does not warp, giving good repulsion to the fingers of the user. Thus, the feeling of key operation is good.
[0092] The four sides of each key of an ordinary keyboard are inclined, whereas the four sides of input keys 13 are not inclined. Accordingly, the occupancy area of each input key 13 is smaller than that of an ordinary key. Accordingly, the gaps between input keys 13 can be widened to prevent the user from pressing wrong input keys 13 .
[0093] The cover 36 has cuts in it, and the input keys 13 and the pointing device 14 are exposed through the cuts. The key-arrangement area is covered with the cover 36 . Thus, the gaps between input keys 13 are covered and, hence, dust and water are prevented from entering through the gaps. The cover 36 and the input keys 13 are made of, for example, ABS resin.
[0094] Now, the upper section 28 of the case 26 will be described below by referring to FIG. 17 . FIG. 17 is a plan view of the inside of the upper section 28 which faces the inside of the lower section 27 shown in FIG. 3 .
[0095] The upper section 28 is almost rectangular and has approximately the same area as the lower section 27 . The upper section 28 has a large cut 80 in its front area wherein the input keys 13 and the pointing device 14 are arranged.
[0096] The reference numeral 81 in FIG. 17 is a covered area. Outward-protruding constituent parts 74 a and 74 b of the hinges “h” are formed at the back side of the covered area 81 .
[0097] A heat-transmitting sheet 72 is stuck to the inside of the covered area 81 . The heat-transmitting sheet 72 is positioned near to the center between the right and left sides of the covered area 81 .
[0098] The heat-transmitting sheet 72 is made of, for example, graphite and 0.1-1.0 mm thick. The heat-transmitting sheet 72 is shaped and has cuts in it so as to avoid bosses and ribs erected inside the covered area 81 . Thus, the covered area 81 is not floated over the inside surface of the covered area 81 , but closely stuck onto the inside surface; accordingly, the heat from heat-generating components is effectively diffused through the upper section 28 .
[0099] An elastic sheet 83 is laid between the heat-transmitting sheet 72 and the inside surface of the covered area 81 . The elastic sheet 83 is rectangular and larger than the heat-generating components in contact with the heat-transmitting sheet 72 . The elastic sheet 83 is positioned near to the center between the right and left sides of the covered area 81 .
[0100] To be specific, the elastic sheet 83 is 0.5-3.0 mm thick and made of Poron (of Rogers Inoac Corporation) which is high-density polyurethane foam whose cells are fine and uniform.
[0101] An insulating sheet (not shown) is overlaid on the heat-transmitting sheet 72 ; accordingly, short circuits between the heat-transmitting sheet 72 , which is made of graphite and conductive, and the motherboard 30 , which is put on the heat-transmitting sheet 72 , are prevented.
[0102] The insulating sheet is, for example, a transparent film of polyphenylene sulfide. It is as thin as, for example, 0.05-0.3 mm; therefore, it does not prevent heat transmission from the heat-generating components to the heat-transmitting sheet 72 .
[0103] The lower section 27 and the upper section 28 are coupled by, for example, screws. At this time, the keyboard 11 , motherboard 30 , hard-disk drive 32 , and PC card slot 34 are fitted in the inside of the lower section 27 .
[0104] The cooling mechanism for the central processor 58 and the image processor 60 , which are mounted on the upper and lower surfaces, respectively, of the motherboard 30 and generate heat, will be described below by referring to FIG. 18 .
[0105] The lower surface, on which the image processor 60 is mounted, of the motherboard 30 faces the inside of the lower section 27 . The upper surface, on which the central processor 58 is mounted, faces the inside of the upper section 28 .
[0106] The image processor 60 is in contact with the part of the heat-transmitting sheet 47 raised by the elastic sheet 48 . In this way, the image processor 60 is put in close contact with the heat-transmitting sheet 47 by the elasticity of the elastic sheet 48 . Thus, air is precluded from between the image processor 60 and the heat-transmitting sheet 47 and the heat from the image processor 60 is efficiently transmitted to the heat-transmitting sheet 47 .
[0107] The heat transmitted to the heat-transmitting sheet 47 is diffused through the heat-transmitting sheet 47 and the lower section 27 . Thus, overheat of the image processor 60 is prevented.
[0108] The central processor 58 is in contact with the part of the heat-transmitting sheet 72 lowered by the elastic sheet 83 . In this way, the central processor 58 is put in close contact with the heat-transmitting sheet 72 by the elasticity of the elastic sheet 83 . Thus, air is precluded from between the central processor 58 and the heat-transmitting sheet 72 and the heat from the central processor 58 is efficiently transmitted to the heat-transmitting sheet 72 .
[0109] The heat transmitted to the heat-transmitting sheet is diffused through the heat-transmitting sheet 72 and the upper section 28 . Thus, overheat of the central processor 58 is prevented.
[0110] The central processor 58 and the image processor 60 are so positioned that they do not overlap with each other and, hence, the heat from the central processor 58 and the image processor 60 is not concentrated at a single spot. Beside, this arrangement of the central processor 58 and the image processor 60 enables the reduction of the distance between the lower section 27 and the upper section 28 and, hence, the reduction of the body 3 .
[0111] The semiconductor memories 62 (see FIG. 7 ) mounted on the lower surface of the motherboard 30 are also in contact with the heat-transmitting sheet 47 and their heat is diffused through the heat-transmitting sheet 47 .
[0112] The hard-disk drive 32 as that is a storage device, which is positioned to the left of the motherboard 30 in FIG. 5 , will be described below.
[0113] As shown in FIG. 3 , ribs 46 are formed in the four corners of a hard disk drive-mounting space 44 in the lower section 27 . In addition, as shown in FIG. 17 , ribs 78 are formed in the four corners of a hard disk drive-mounting space 76 in the upper section 28 .
[0114] Accordingly, the hard-disk drive 32 is supported by the ribs 46 and 78 , a gap of the height of ribs 78 kept between the top surface of the hard-disk drive 32 and the inside surface of the upper section 28 , a gap of the height of ribs 46 kept between the bottom surface of the hard-disk drive 32 and the inside surface of the lower section 27 .
[0115] There are small gaps in spots, where the connectors 40 a - d (see FIG. 5 ) are mounted to expose their sockets, of the left side plates of the lower section 27 and the upper section 28 . The inside and the outside of the case 26 are connected by the small gaps. The space in which the motherboard 30 is fitted and the outside of the case 26 can be connected by the small gaps and the gaps on and under the hard-disk drive 32 .
[0116] Accordingly, the discharge of heat from the central processor 58 and the image processor 60 can be accelerated. Besides, the hard-disk drive 32 can be air-cooled.
[0117] The connectors 40 a - d are connected to the motherboard through the flexible wiring board 67 (see FIG. 8 ). The flexible wiring board 67 is routed through the gap between the bottom surface of the hard-disk drive 32 and the inside surface of the lower section 27 .
[0118] Because the connectors 40 a - d are not mounted directly on the motherboard 30 , shock at the time of connection and disconnection of external cables to and from the connectors 40 a - d is absorbed by the flexible wiring board 67 . Thus, the shock is not transmitted to the motherboard 30 , damage to and positional slippage of the motherboard 30 prevented.
[0119] As shown in FIGS. 8 and 9 , the connectors 40 b and 40 c are disposed so that the right flange 64 of the connector 40 b and the left flange 64 of the connector 40 c overlap with each other. The two flanges 64 overlapping with each other are fixed to the left side plate of the lower section 27 with, for example, a screw. Thus, the space to mount the connectors 40 a - d is saved by the space of one flange 64 .
[0120] As shown in FIG. 5 , the PC card slot 34 is disposed at the right side of the case 26 . The PC card is the standards for card-type peripheral devices established jointly by PCMCIA (Personal Computer Memory Card International Association) and JEIDA (Japan Electronic Industry Development Association).
[0121] The keyboard 11 is disposed in the space along the front of the case 26 . The input keys 13 and the pointing device 14 are exposed to the outside through the cut 80 in the upper section 28 .
[0122] As described above, the motherboard 30 , hard-disk drive 32 , and PC card slot 34 are disposed in the space along the back of the case 26 and the keyboard 11 is disposed in the space along the front of the case 26 .
[0123] Cuts are made in the right and left sides of the motherboard 30 to avoid the hard-disk drive 32 and the PC card slot 34 . The keyboard 11 does not overlap with the central processor 58 or the image processor 60 mounted on the motherboard 30 or the hard-disk drive 32 or the PC card slot 34 .
[0124] As described above, because built-in components are arranged without their overlapping with one another, the body 3 can be made thin.
[0125] Part of the motherboard 30 is placed under the keyboard 11 , but the central processor 58 and the image processor 60 , which account for a large part of the thickness of the motherboard 30 , do not overlap with the keyboard 11 . Accordingly, the body 3 is not prevented from being made thin. An insulating sheet made of, for example, polycarbonate is laid between the part of the motherboard 30 overlapping with the keyboard 11 and the keyboard 11 in order to prevent short circuits between the case 37 of conductive magnesium and the motherboard 30 . The motherboard 30 and the keyboard 11 may be arranged so that they do not overlap with each other at all.
[0126] Because the heat-generating central processor 58 and image processor 60 do not overlap with the keyboard 11 , the heat of neither the central processor 58 nor the image processor 60 is transmitted to the keyboard 11 to annoy the user.
[0127] Because the central processor 58 and the image processor 60 are disposed in the space along the back side of the case 26 and the keyboard 11 is disposed in the space along the front side of the case 26 , the user can operate the keyboard 11 without touching the upper section 28 covering the central processor 58 and the image processor 60 .
[0128] The central processor 58 and the image processor 60 are positioned near to the center between the right and left sides of the case 26 ; accordingly, less heat is transmitted from the central processor 58 and the image processor 60 to the user's right and left hands which tend to be positioned toward the right and left sides of the keyboard 11 , respectively. When the user moves the electronic device 1 with the display 5 opened, the user holds the right and left sides of the part of the body 3 behind the keyboard 11 ; accordingly, less heat is transmitted from the central processor 58 and the image processor 60 to the hands of the user.
[0129] Because the most heat-generating image processor 60 is mounted on the lower surface of the motherboard 30 , less heat is transmitted from the image processor 60 to the top, or keyboard, side of the body 3 , less annoying the user.
[0130] Now, the display 5 will next be described. The display 5 comprises a case 22 (see FIG. 19 ), a liquid crystal panel 7 (see FIG. 21 ) housed in the case 22 , and an inverter circuit board 93 (see FIG. 21 ).
[0131] FIG. 19 is a plan view of the inside of the case 22 . FIG. 20 is a side view of the case 22 as seen along the arrows [ 20 ] and [ 20 ] in FIG. 19 . The case 22 is almost rectangular and side plates are erected at the right and left sides of the case 22 .
[0132] Outward-protruding constituent parts 87 a and 87 b of the hinges “h” are formed at the right and left ends of the back side of the case 22 .
[0133] Molds 85 a - d are provided inside the case 22 . The molds 85 a - d are disposed so that they enclose the four sides of the case 22 and reinforce the case 22 against bending and twisting.
[0134] In the same way as the lower section 27 , the case 22 is made of CFRP (carbon fiber reinforced plastics). To be specific, the CFRP consists of six layers 51 a , 51 b , 52 a , 52 b , 53 a , and 53 b as shown in FIG. 26 .
[0135] As shown in FIG. 26A , the six layers 51 a , 51 b , 52 a , 52 b , 53 a , and 53 b are pressed together.
[0136] Each layer is made of long carbon fibers solidified by epoxy resin. All the fibers of each layer are put side by side in one and the same direction.
[0137] To be concrete, the carbon fibers of the innermost layers 51 a and 51 b are laid in the longitudinal direction of the electronic device 1 . Accordingly, the carbon fibers of the layer 51 a are parallel to those of the layer 51 b.
[0138] The carbon fibers of the intermediate layers 52 a and 52 b are laid in the lateral direction of the electronic device 1 .
[0139] The carbon fibers of the outermost layers 53 a and 53 b are laid in the direction at angles of 45° with the longitudinal and lateral directions of the electronic device 1 . Accordingly, the carbon fibers of the layer 53 a are parallel to those of the layer 53 b.
[0140] With the above laminated structure, the thin case 22 has sufficient strength. As the case 22 as well as the lower section 27 is thin, the electronic device 1 is also thin, which is an advantage for portable electronic devices in particular.
[0141] As shown in FIG. 28 , an insulating layer 56 is formed on the inside surface of the case 22 . The insulating layer 56 is made of, for example, nylon (a trade name of Du Pont).
[0142] The insulating layer 56 prevents short circuits between the case 22 made of CFRP containing conductive carbon fibers and the liquid crystal panel 7 , the inverter circuit board 93 , etc. housed in the case 22 .
[0143] When the insulating layer 56 made of nylon is heated, it softens and becomes adhesive. By making use of the adhesiveness of the insulating layer 56 , the molds 85 a - d are stuck and fixed to the insulating layer 56 . Because the molds 85 a - d are also made of nylon, they stick well to the insulating layer 56 .
[0144] As shown in FIG. 28 , the front and back edges of the case 22 are provided with the molds 85 a and 85 b , respectively. By making use of the adhesiveness of the insulating layer 56 , the molds 85 a and 85 b are stuck onto the insulating layer 56 to cover the front and back edges of the case 22 . Thus, loose ends of carbon fibers, if any, at the front and back edges of the case 22 are covered up.
[0145] Because the molds 85 a and 85 b extend along the front and back edges of the case 22 , they serve as beams, too, reinforcing the case 22 against bending and twisting.
[0146] As shown in FIG. 28 , grooves 54 are made in the surfaces of the molds 85 a and 85 b which come in contact with the insulating layer 56 . When the insulating layer 56 is heated and softened and the molds 85 a and 85 b are stuck on the insulating layer 56 , surplus softened, adhesive nylon enters into the grooves 54 .
[0147] Thus, the surplus softened, adhesive nylon is prevented from leaking out through the joints between the case 22 and the molds 85 a and 85 b . If the surplus softened, adhesive nylon leaks out, the appearance of the electronic device 1 is spoiled.
[0148] Because the case 22 has the right and left side plates, these side plates play the role of the molds 85 a and 85 b.
[0149] The opposite of the inside surface of the case 22 in FIG. 19 is a facing, which is the surface of one of the outmost layers 53 a and 53 b . A layer of self-cure resin is formed on the facing.
[0150] The layer of self-cure resin is formed by spraying, for example, acrylic or urethane resin with cross-linked structure and high capability of elastic recovery to the facing of the case 22 .
[0151] If a flaw or dent is made in the self-cure resin layer on the facing of the case 22 , it exists as a flaw or dent temporarily and then it disappears gradually because of the high capability of elastic recovery of the self-cure resin layer.
[0152] The self-cure resin used in the present embodiment is transparent and colorless. It gives luster to the facing of the case 22 made of dull black CFRP (carbon fiber reinforced plastics) to improve the appearance of the case 22 .
[0153] The unit consisting of the liquid crystal panel 7 and the inverter circuit board 93 shown in FIG. 21 is fitted in the inside of the case 22 of FIG. 19 . Because the inverter circuit board 93 does not overlap with the liquid crystal panel 7 as shown in FIG. 21 , the display 5 is thin. The thinness of the display 5 as well as the thinness of the body 3 contributes to the thinness of the electronic device 1 .
[0154] The liquid crystal panel 7 has a back-light unit including a light source, light-guiding plates, etc. A fluorescent lamp, for example, is used as the light source, which may be built in the top of the liquid crystal panel 7 .
[0155] As shown in FIG. 19 , a piece of conductor foil 89 such as copper foil is stuck on the inside surface of the case 22 to earth the liquid crystal panel 7 to the case 22 .
[0156] In general, there exists a thin resin film (for example, an epoxy-resin film) on the surface of a base plate made of CFRP; accordingly, the surface of the base plate does not have stable conductivity. As in FIG. 27 , if a piece of copper foil 89 is pressed onto a resin film 127 on the surface of the outermost layer 53 a , the piece of copper foil 89 pushes aside the resin film 127 and sticks to the layer 53 a to secure a stable electric connection between the piece of copper foil 89 and the conductive carbon fibers of the layer 53 a.
[0157] As shown in FIG. 22 , a leaf spring 95 is fitted between the piece of copper foil 89 on the inside of the case 22 and a metal bracket 91 a mounted on a metal frame 91 of the liquid crystal panel 7 to electrically connect the liquid crystal panel 7 to the piece of copper foil 89 . The tip of the leaf spring 95 is in elastic contact with the piece of copper foil 89 and the base of the leaf spring 95 is fixed to the metal bracket 91 a by, for example, a screw.
[0158] Thus, the liquid crystal panel 7 is electrically stably connected to the case 22 with a large area to protect the liquid crystal panel 7 from external magnetic noises and prevent the magnetic noises generated by the liquid crystal panel 7 from affecting external components and devices.
[0159] As shown in FIG. 1 , a frame 24 is fitted to the case 22 housing the liquid crystal panel 7 to expose the screen 70 of the liquid crystal panel 7 .
[0160] The hinges “h” to connect the body 3 and the display 5 will next be described below.
[0161] When the lower section 27 of FIG. 3 and the upper section 28 of FIG. 17 are combined, the part 42 a of the lower section 27 and the part 74 a of the upper section 28 are combined to become a cylinder of a hinge “h.” One hinge h (the left hinge h in FIGS. 1 and 2 ) is constructed when the cylinder of the case 26 is rotatably connected with the constituent part 87 a of the case 22 shown in FIG. 19 .
[0162] On the other hand, when the lower section 27 of FIG. 3 and the upper section 28 of FIG. 17 are combined, the part 42 b of the lower section 27 and the part 74 b of the upper section 28 are combined to become another cylinder. The other hinge h (the right hinge h in FIGS. 1 and 2 ) is constructed when the cylinder of the case 26 is rotatably connected with the constituent part 87 b of the case 22 shown in FIG. 19 .
[0163] As shown in FIG. 23 , a hinge fitting 97 is provided on the other hinge h. One end of the hinge fitting 97 is fixed to the cylinder of the case 26 by, for example, a screw. The constituent part of the case 22 receives a cylindrical portion of the hinge fitting 97 , and the case 22 , or the display 5 , is relatively rotatable about the cylindrical portions of the hinge fittings 97 .
[0164] Further, as shown in FIG. 23 , a power switch 20 is provided on an edge of the hinge's shaft (a side portion which does not face the other hinge with respect to the longitudinal direction of the axis of the hinge, namely, a side portion on the right in FIG. 23 ). (Also, see FIG. 2 )
[0165] The power switch 20 comprises, as shown in a schematic diagram of FIG. 25 , a pressing operation part 101 , a light-emitting element 121 , a switch 125 , and a contact 123 .
[0166] The pressing operation part 101 can be pressed along the longitudinal direction of the axis of the hinge (the direction shown by the arrow in FIG. 25 ). The light-emitting element 121 is placed inside the pressing operation part 101 . The light-emitting element 121 is, for example, a light-emitting diode and is mounted on a surface, which faces the pressing operation part 101 , of the circuit board 103 joined with the pressing operation part 101 .
[0167] The switch 125 is mounted on the other side of the circuit board 103 . The contact 123 provided facing the switch 125 is fixed to the constituent part of the case 22 .
[0168] As shown in FIG. 2 , the pressing operation part 101 is exposed to the outside. When the pressing operation part 101 is pressed in the direction of the arrow in FIG. 25 by a user's finger and so on, it moves toward the contact 123 together with the circuit board 103 , and the light-emitting element 121 and the switch 125 mounted thereon.
[0169] When the switch 125 is pressed touching the contact 123 , the power is turned off when the power of the electronic device 1 is on and the power is turned on when the power of the electronic device 1 is off.
[0170] When the pressing operation part 101 is pressed sideways by the user's finger, the direction of the movement tends to be inclined compared to when it is pressed downward. To cope with such a problem, the surface of the switch 125 which meets the contact 123 is curved. Therefore, in spite of a little inclination, the contact and the switch 125 can meet stably (for example, compared to when the surface is flat, the contact area can be larger) and the power can be turned on or off reliably.
[0171] Incidentally, the pressing operation part 101 has substantially a round shape, and is disposed so that the rotation axis of the hinge will pierce substantially the center of the round pressing operation part 101 . Consequently, when the power switch is pressed in the direction of the rotation axis of the hinge, the power supply is turned on or off. Since the switch 125 is pressed in the direction of the rotation axis of the hinge, the pressing operation part 101 that is large for the thickness of the display 5 or the body 3 can be employed. Consequently, the power switch 20 is reliably manipulated.
[0172] According to the present embodiment, the pressing operation part 101 that is large for the thickness of the display 5 or body 3 is adopted. As long as the pressing operation part 101 that is pressed in the direction of the rotation axis of the hinge is adopted, the pressing operation part 101 (switch or button) that is larger than a switch (button) to be formed in the lateral side of the case can be formed because of the thicknesses of the cases 22 , 24 , 27 , and 28 that determine the shapes of the display 5 and body 3 respectively.
[0173] The usage of the space in the hinge is not limited to the power switch as it is in the present embodiment. Alternatively, a switch (button) for any purpose other than the purpose of power supply may be formed. For example, when electronic device includes an imaging means that has a CCD or the like, the space in the hinge may be used to form a shutter button required for producing still images or an imaging start/stop button required for producing a motion picture.
[0174] Further, if all or a part (for example, a ring portion of the outer edge) of the portion of the pressing operation part 101 exposed to the outside is formed as a light-transmission part made of transparent resin material, the light from the light-emitting element 121 can be guided to the outside through such a light-transmission part. Accordingly, when the power is on, for example, a red light can be turned on to have a user confirm its state visually. Alternatively, when in a power-saving standby state, a green light can be turned on and off to have the user confirm its state visually.
[0175] The light transmission part of the pressing operation part 101 is always exposed to the outside regardless of the electronic device 1 being opened or closed. Therefore, even if the display 5 is closed while the power is on, the state can be checked by the light visible through the light transmission part.
[0176] Also, when carrying the electronic device 1 in a bag or so with the display 5 closed, the pressing operation part 101 may be pressed by an article in the bag. Accordingly, in the present embodiment, as in FIG. 23 , a closed-state detecting switch 105 is provided on the constituent part of the case 22 , and a closed-state detecting contact 106 is provided on the hinge fitting 97 as a single piece.
[0177] When the display 5 is closed onto the body 3 by the relative rotation of the constituent part of the case 22 and the hinge fitting 97 , the closed-state detecting switch and the closed-state detecting contact 106 meet, turning on the closed-state detecting switch 105 . The closed-state detecting switch 105 is kept turned on while the display 5 is closed onto the body 3 .
[0178] Accordingly, when the closed-state detecting switch 105 is on, that is, when the display is closed, the electronic device 1 can be prevented from being turned on even if the pressing operation part 10 is pressed. Alternatively, when it is closed while the power is on and the closed-state detecting switch 105 is turned on, it becomes possible to automatically turn the power off or to send the electronic device 1 into a power-saving standby state.
[0179] Incidentally, a control mode is not limited to the mode of controlling the power supply according to whether the display is open or closed, but any other control mode may be adopted.
[0180] For example, when electronic device has an imaging means that includes a CCD, the action of a shutter button required for producing still images or an imaging start/stop button required for producing a motion picture may be controlled based on whether the case is open or closed. For example, control is extended so that when the case is closed, even if the button is pressed, a still image or a motion picture will not be produced.
[0181] Incidentally, the means for detecting whether the display 5 is open or closed is not limited to the one employed in the present embodiment, but any other means will do. For example, a magnetic body included in the display 5 , and a Hall sensor that is located in a region in the body 3 in which the Hall sensor is opposed to the magnetic body and that detects a magnetic field strength may be used to detect whether the display is open or closed.
[0182] Further, as in FIG. 24 , a connector 19 for an AC adapter is provided on the edge (side portion on the left in FIG. 24 ) of the shaft of the hinge opposite the hinge in which the power switch 20 is provided (Also, see FIG. 1 ). A socket for the connector 19 is always exposed to the outside regardless of the opened and closed state of the electronic device 1 .
[0183] Moreover, the connector 19 is disposed so that the rotation axis of the hinge and the axis of the connector 19 will be aligned with each other.
[0184] Since the port of the connector 19 opens in the direction of the rotation axis of the hinge, the connector that is large for the thickness of the display 5 or body 3 can be employed.
[0185] According to the present embodiment, the connector 19 that is large for the thickness of the display 5 or body 3 is employed. As long as the port of the connector opens in the direction of the rotation axis of the hinge, a connector larger than the one formed in the lateral side of any of the cases 22 , 24 , 27 , and 28 , which determine the shapes of the display 5 and body 3 respectively, can be formed because of the thicknesses of the cases.
[0186] The usage of the space in the hinge is not limited to the connector for connection of an AC adaptor as it is in the present embodiment. A connector for any purpose other than the purpose of power supply may be formed. For example, a connector for connection of a headphone may be formed. Moreover, the shape of the port of the connector is not limited to a round but may be a rectangle. For example, a connector for plugging in of a universal serial bus (USB) 2.0 may be formed.
[0187] As in FIG. 24 , a cable 112 for connecting the connector 19 with the motherboard 30 of the body 3 is not directed straight from the connection with the connector 19 to the side of the body 3 (lower position in FIG. 24 ). On the contrary, the cable 112 detours around the area near the connection with the connector 19 so that it forms a loop on the side of the display 5 and is drawn to the side of the body 3 .
[0188] The detouring portion of the cable 112 forms a loop being guided by a boss 114 erected inside the case 22 and guide members 118 , 119 a , 119 b.
[0189] Accordingly, even if opening and closing of the display 5 away from and onto the body 3 are repeated, the connection (soldered, for example) to the connector 19 of the cable 112 is prevented from receiving a concentrated excessive load such as twisting and pulling, thereby a break in the cable being prevented.
[0190] Further, the guide members 119 a and 119 b restrict the rising of the detouring portion of the cable 112 from the inside surface of the case 22 so that the looped detouring portion can be held stably.
[0191] Further, the previously described power switch 20 shown in FIG. 23 is configured such that a cable (not shown) connected to the connector 110 via the flexible wiring board 108 formed on the inside surface of the case 22 is drawn to the side of the body 3 . Therefore, again, the cable is not drawn directly from the power switch 20 to the body 3 . This is because the previously described inverter circuit board 93 is not provided on the inside surface of the case 22 on this side and there is enough space for arranging the above flexible wiring board 108 and the connector 110 .
[0192] As described above, the power switch 20 and the connector 19 are provided on the edge portion of the shaft of the hinge, which has not been used at all, namely, a dead space. Therefore, components of the body 3 and the display 5 can be positioned more freely. By suitably arranging those components, the body 3 and the display 5 can be made thinner as described above. Further, since the power switch 20 is positioned away from the keyboard 11 and other operation buttons 15 a - 15 c (see FIG. 1 ), it is prevented from being mistakenly pressed, ensuring reliable operation. Thus, mistakes such as turning the power off while the device is in use can be avoided.
[0193] The embodiment has been described by taking for instance the electronic device including the display 5 and body 3 that can be freely turned on the hinges to be open or closed. The present invention can be adapted to any other type of electronic device as long as a first case and a second case can be freely turned on hinges to be open or closed. For example, electronic device including two displays that can be freely turned on hinges to be open or closed will do.
[0194] Moreover, according to the aforesaid embodiment, the hinges are formed on the edge of the case of electronic device away from a user under the normal specifications. Alternatively, electronic device whose right and left cases are turned on hinges to be open or closed will do.
[0195] Functions such as left-clicking, right-clicking, and scrolling are assigned to the three operation buttons 15 a - c disposed on the front edge about the center between the right and left sides of the body 3 .
[0196] Also, as shown in FIGS. 1 and 2 , there is a battery 9 provided between the hinges h.
[0197] Further, as shown in FIGS. 1 and 2 , a bottom surface of the lower section 27 is not flat, and the rear end on the side of the hinges h is curved (so that it rises a little from the surface where the electronic device is placed). Compared to the bottom surface of the lower section 27 being flat, this structure reinforces the lower section 27 against bending and twisting.
[0198] Also, as shown in FIG. 29 , a stopper 130 is provided on a periphery of each hinge h facing backward of the electronic device 1 . when the display 5 is opened, the display 5 is prevented from opening further by the lower edge of the display 5 meeting the stopper 130 . For example, in the present embodiment, the angle of opening (an angle formed by the body 3 and the display 5 ) is restricted to 135°.
[0199] Further, as shown in FIGS. 2 and 30 , tapered portions 68 and 69 are formed respectively at the front edges of the case 26 and the case 22 facing with each other so that the front edges make a V-shape when the display 5 is closed onto the body 3 .
[0200] The tapered portion 68 is inclined upward toward the front, and the tapered portion 69 is inclined downward toward the front. The distance between the tapered portions 68 and 69 in a closed state, namely, when the case 26 and the case 22 are closed, gradually increases toward the front.
[0201] With such a structure, even if the body 3 and the display 5 are very thin like the ones in the present embodiment, the front edge of the display 5 can easily be lifted from the body 3 staying where it is by putting a finger in a V-shaped area between the tapered portions 68 , and hooking the tapered portion 68 of the case 22 with a fingertip.
[0202] Further, as shown in FIGS. 1 and 2 , various indicator lamps 17 a - 17 c provided in the front edge of the body 3 extend to the downwardly inclined area of the front edge. Therefore, even when the display 5 is closed as in FIG. 2 , the above various indicator lamps 17 a - 17 c are visible to the user.
[0203] Although the invention has been described in its preferred form, it is to be understood that the invention is not limited to the specific embodiments thereof and various changes and modifications may be made without departing from the sprit and the scope of the invention.
[0204] Instead of the PC card slot of the body 3 , any other semiconductor-memory card slot may be provided.
[0205] Further, the heat-transmitting sheets 72 and 47 may be stuck to the inside of the upper section 28 and an entire surface of the inside of the lower section 27 , respectively. | A power switch and connector that are conventionally included in a body are formed in spaces created at the outer ends of the shafts of hinges other than the body and a display, whereby the body is thinned. Electronic device comprises a body, a display, and a hinge that joins the body and display so that they can be freely opened or closed. A power switch is formed at an end of the shaft of the hinge. Furthermore, the electronic device comprises the body, the display, and another hinge that joins the body and display so that they can be freely opened or closed. A port of a connector opens at an end of the shaft of the hinge. | 58,424 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of copending U.S. utility application entitled, “Higher Picture Rate HD Encoding and Transmission with Legacy HD Backward Compatibility,” having Ser. No. 11/132,060, filed May 18, 2005, which is entirely incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention relates to digital television and, more specifically to receivers with different capabilities for receiving, processing and displaying the same emission of a compressed video signal, each receiver providing one in a plurality of picture formats according to its respective capability.
BACKGROUND OF THE INVENTION
[0003] There are many different digital television compressed video picture formats, some of which are HD. HDTV currently has the highest digital television spatial resolution available. The picture formats currently used in HDTV are 1280×720 pixels progressive, 1920×1080 pixels interlaced, and 1920×1080 pixels progressive. These picture formats are more commonly referred to as 720P, 1080i and 1080P, respectively. The 1080i format, which comprises of interlaced pictures, each picture or frame being two fields, shows 30 frames per second and it is deemed as the MPEG-2 video format requiring the most severe consumption of processing resources. The 1080P format shows 60 frames per second, each frame being a progressive picture, and results in a doubling of the most severe consumption of processing resources. A receiver capable of processing a maximum of 1080i-60 is also capable of processing a maximum 1080P-30. However, broadcasters intend to introduce 1080P-60 emissions and CE manufacturers intend to provide HDTVs and HDTV monitors capable of rendering 1080P-60, in the near future. 1080P-60 includes twice as much picture data as either 1080i-60 or 1080P-30. Dual carrying channels or programs as 1080P-60 and 1080i-60 would not be an acceptable solution because it triples the channel consumption of a single 1080i-60 transmission.
[0004] Therefore, there is a need for encoding 1080P-60 video for transmission in a way that facilitates the superior picture quality benefits of a 1080P-60 signal to 1080P-60 capable receivers while simultaneously enabling legacy 1080i-60 capable receivers to fulfill the equivalent of a 1080P-30 signal from the transmitted 1080P-60 signal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a high-level block diagram depicting a non-limiting example of a subscriber television system.
[0006] FIG. 2 is a block diagram of a DHCT in accordance with one embodiment of the present invention.
[0007] FIG. 3 illustrates program specific information (PSI) of a program having elementary streams including encoded video streams which may be combined to form a single video stream encoded as 1080P-60.
[0008] FIG. 4A illustrates first and second video streams in display order.
[0009] FIG. 4B illustrates pictures according to picture types in display order.
[0010] FIG. 4C illustrates transmission order of the pictures in display order of FIG. 2B .
DETAILED DESCRIPTION
[0011] The present invention will be described more fully hereinafter with reference to the accompanying drawings in which like numerals represent like elements throughout the several figures, and in which an exemplary embodiment of the invention is shown. This invention may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, the embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. The present invention is described more fully hereinbelow.
[0012] It is noted that “picture” is used throughout this specification as one from a sequence of pictures that constitutes video, or digital video, in one of any of a plurality of forms. Furthermore, in this specification a “frame” means a picture, either as a full progressive picture or in reference to a whole instance of a full frame comprising both fields of an interlaced picture.
Video Decoder in Receiver
[0013] FIG. 1 is a block diagram depicting a non-limiting example of a subscriber television system (STS) 100 . In this example, the STS 100 includes a headend 110 and a DHCT 200 that are coupled via a network 130 . The DHCT 200 is typically situated at a user's residence or place of business and may be a stand-alone unit or integrated into another device such as, for example, the display device 140 or a personal computer (not shown). The DHCT 200 receives signals (video, audio and/or other data) including, for example, MPEG-2 streams, among others, from the headend 110 through the network 130 and provides any reverse information to the headend 110 through the network 130 . The network 130 may be any suitable means for communicating television services data including, for example, a cable television network or a satellite television network, among others. The headend 110 may include one or more server devices (not shown) for providing video, audio, and textual data to client devices such as DHCT 200 . Television services are provided via the display device 140 which is typically a television set. However, the display device 140 may also be any other device capable of displaying video images including, for example, a computer monitor.
[0014] FIG. 2 is a block diagram illustrating selected components of a DHCT 200 in accordance with one embodiment of the present invention. It will be understood that the DHCT 200 shown in FIG. 2 is merely illustrative and should not be construed as implying any limitations upon the scope of the preferred embodiments of the invention. For example, in another embodiment, the DHCT 200 may have fewer, additional, and/or different components than illustrated in FIG. 2 . A DHCT 200 is typically situated at a user's residence or place of business and may be a stand alone unit or integrated into another device such as, for example, a television set or a personal computer. The DHCT 200 preferably includes a communications interface 242 for receiving signals (video, audio and/or other data) from the headend 110 through the network 130 ( FIG. 1 ) and for providing any reverse information to the headend 110 .
[0015] DHCT 200 is referred to as a receiver such as receiver 200 throughout this specification. The DHCT 200 further preferably includes at least one processor 244 for controlling operations of the DHCT 200 , an output system 248 for driving the television display 140 , and a tuner system 245 for tuning to a particular television channel or frequency and for sending and receiving various types of data to/from the headend 110 . The DHCT 200 may, in another embodiment, include multiple tuners for receiving downloaded (or transmitted) data. Tuner system 245 can select from a plurality of transmission signals provided by the subscriber television system 100 , including a 1080P-60 program. Tuner system 245 enables the DHCT 200 to tune to downstream media and data transmissions, thereby allowing a user to receive digital media content such as a 1080P-60 program via the subscriber television system. The tuner system 245 includes, in one implementation, an out-of-band tuner for bi-directional quadrature phase shift keying (QPSK) data communication and a quadrature amplitude modulation (QAM) tuner (in band) for receiving television signals. Additionally, a user command interface 246 receives externally-generated user inputs or commands from an input device such as, for example, a remote control. User inputs could be alternatively received via communication port 274 .
[0016] The DHCT 200 may include one or more wireless or wired interfaces, also called communication ports 274 , for receiving and/or transmitting data to other devices. For instance, the DHCT 200 may feature USB (Universal Serial Bus), Ethernet, IEEE-1394, serial, and/or parallel ports, etc. DHCT 200 may also include an analog video input port for receiving analog video signals. User input may be provided via an input device such as, for example, a hand-held remote control device or a keyboard.
[0017] The DHCT 200 includes signal processing system 214 , which comprises a demodulating system 213 and a transport demultiplexing and parsing system 215 (herein demultiplexing system) for processing broadcast media content and/or data. One or more of the components of the signal processing system 214 can be implemented with software, a combination of software and hardware, or preferably in hardware. Demodulating system 213 comprises functionality for demodulating analog or digital transmission signals. For instance, demodulating system 213 can demodulate a digital transmission signal in a carrier frequency that was modulated, among others, as a QAM-modulated signal. When tuned to a carrier frequency corresponding to an analog TV signal, demultiplexing system 215 is bypassed and the demodulated analog TV signal that is output by demodulating system 213 is instead routed to analog video decoder 216 . Analog video decoder 216 converts the analog TV signal into a sequence of digitized pictures and their respective digitized audio. The analog TV decoder 216 and other analog video signal components may not exist in receivers or DHCTs that do not process analog video or TV channels.
[0018] A compression engine in the headend processes a sequence of 1080P-60 pictures and associated digitized audio and converts them into compressed video and audio streams, respectively. The compressed video and audio streams are produced in accordance with the syntax and semantics of a designated audio and video coding method, such as, for example, MPEG-2, so that they can be interpreted by video decoder 223 and audio decoder 225 for decompression and reconstruction after transmission of the two video streams corresponding to the 1080P-60 compressed signal. Each compressed stream consists of a sequence of data packets containing a header and a payload. Each header contains a unique packet identification code, or packet_identifier (PID) as is the casein MPEG-2 Transport specification, associated with the respective compressed stream. The compression engine or a multiplexer at the headend multiplexes the first and second video streams into a transport stream, such as an MPEG-2 transport stream.
[0019] Video decoder 223 may be capable of decoding a first compressed video stream encoded according to a first video specification and a second compressed video stream encoded according to a second video specification that is different than the first video specification. Video decoder 223 may comprise of two different video decoders, each respectively designated to decode a compressed video stream according to the respective video specification.
[0020] Parsing capabilities 215 within signal processing 214 allow for interpretation of sequence and picture headers. The packetized compressed streams can be output by signal processing 214 and presented as input to media engine 222 for decompression by video decoder 223 and audio decoder 225 for subsequent output to the display device 140 ( FIG. 1 ).
[0021] Demultiplexing system 215 can include MPEG-2 transport demultiplexing. When tuned to carrier frequencies carrying a digital transmission signal, demultiplexing system 215 enables the separation of packets of data, corresponding to the desired video streams, for further processing. Concurrently, demultiplexing system 215 precludes further processing of packets in the multiplexed transport stream that are irrelevant or not desired such as, for example in a 1080i-60 capable receiver, packets of data corresponding to the second video stream of the 1080P-60 program.
[0022] The components of signal processing system 214 are preferably capable of QAM demodulation, forward error correction, demultiplexing MPEG-2 transport streams, and parsing packetized elementary streams and elementary streams. The signal processing system 214 further communicates with processor 244 via interrupt and messaging capabilities of DHCT 200 .
[0023] The components of signal processing system 214 are further capable of performing PID filtering to reject packetized data associated with programs or services that are not requested by a user or unauthorized to DHCT 200 , such rejection being performed according to the PID value of the packetized streams. PID filtering is performed according to values for the filters under the control of processor 244 . PID filtering allows for one or more desired and authorized programs and/or services to penetrate into DHCT 200 for processing and presentation. PID filtering is further effected to allow one or more desired packetized streams corresponding to a program (e.g., a 1080P — 60 program) to penetrate DHCT 200 for processing, while simultaneously rejecting one or more different packetized stream also corresponding to the same program. Processor 244 determines values for one or more PIDS to allow to penetrate, or to reject, from received information such as tables carrying PID values as described later in this specification. In an alternate embodiment, undesirable video streams of a program are allowed to penetrate into DHCT 200 but disregarded by video decoder 223 .
[0024] A compressed video stream corresponding to a tuned carrier frequency carrying a digital transmission signal can be output as a transport stream by signal processing 214 and presented as input for storage in storage device 273 via interface 275 . The packetized compressed streams can be also output by signal processing system 214 and presented as input to media engine 222 for decompression by the video decoder 223 and audio decoder 225 .
[0025] One having ordinary skill in the art will appreciate that signal processing system 214 may include other components not shown, including memory, decryptors, samplers, digitizers (e.g. analog-to-digital converters), and multiplexers, among others. Further, other embodiments will be understood, by those having ordinary skill in the art, to be within the scope of the preferred embodiments of the present invention. For example, analog signals (e.g., NTSC) may bypass one or more elements of the signal processing system 214 and may be forwarded directly to the output system 248 . Outputs presented at corresponding next-stage inputs for the aforementioned signal processing flow may be connected via accessible memory 252 in which an outputting device stores the output data and from which an inputting device retrieves it. Outputting and inputting devices may include analog video decoder 216 , media engine 222 , signal processing system 214 , and components or sub-components thereof. It will be understood by those having ordinary skill in the art that components of signal processing system 214 can be spatially located in different areas of the DHCT 200 .
[0026] In one embodiment of the invention, a first and second tuners and respective first and second demodulating systems 213 , demultiplexing systems 215 , and signal processing systems 214 may simultaneously receive and process the first and second video streams of a 1080P-60 program, respectively. Alternatively, a single demodulating system 213 , a single demultiplexing system 215 , and a single signal processing system 214 , each with sufficient processing capabilities may be used to process the first and second video streams in a 1080P-60 capable receiver.
[0027] The DHCT 200 may include at least one storage device 273 for storing video streams received by the DHCT 200 . A PVR application 277 , in cooperation with the operating system 253 and the device driver 211 , effects, among other functions, read and/or write operations to the storage device 273 . The device driver 211 is a software module preferably resident in the operating system 253 . The device driver 211 , under management of the operating system 253 , communicates with the storage device controller 279 to provide the operating instructions for the storage device 273 . Storage device 273 could be internal to DHCT 200 , coupled to a common bus 205 through a communication interface 275 .
[0028] Received first and second video streams are deposited transferred to DRAM 252 , and then processed for playback according to mechanisms that would be understood by those having ordinary skill in the art. In some embodiments, the video streams are retrieved and routed from the hard disk 201 to the digital video decoder 223 and digital audio decoder 225 simultaneously, and then further processed for subsequent presentation via the display device 140 .
[0029] Compressed pictures in the second video stream may be compressed independent of reconstructed pictures in the first video stream. On the other hand, an aspect of the invention is that pictures in the second video stream, although compressed according to a second video specification that is different to the first video specification, can depend on decompressed and reconstructed pictures in the first video stream for their own decompression and reconstruction.
[0030] Examples of dependent pictures are predicted pictures that reference at most one picture (from a set of at least one reconstructed picture) for each of its sub-blocks or macroblocks to effect its own reconstruction. That is, predicted pictures in the second video stream, can possibly depend one or more referenced pictures in the first video stream.
[0031] Bi-predicted pictures (B-pictures) can reference at most two pictures from a set of reconstructed pictures for reconstruction of each of its sub-blocks or macroblocks to effect their own reconstruction.
[0032] In one embodiment, pictures in the second video stream reference decompressed and reconstructed pictures (i.e., reference pictures) from the first video stream. In another embodiment, pictures in the second video stream employ reference pictures from both the first and second video streams. In yet another embodiment, a first type of picture in the second video stream references decompressed pictures from the second video stream and a second type of picture references decompressed pictures from the first video stream.
[0000] Enabling Receivers with Different Capabilities
[0033] The present invention includes several methods based on two separate video streams assigned to a program rather than a single stream with inherent built-in temporal scalability. Existing receivers capable of processing 1080i-60 video streams today would be deemed “legacy HD receivers” at the time that broadcasters start emissions of 1080P-60 programs. If a 1080P-60 program was transmitted without the advantage of this invention the “then” legacy HD receivers would not know how to process a 1080P-60 video stream, nor be capable of parsing the video stream to extract a 1080P-30 signal from the received 1080P-60. The legacy HD receivers were not designed to identify and discard pictures from a single 1080P-60 video stream. Furthermore, 1080P-60 in the standard bodies is specified for a 1080P-60 receiver without backward compatibility to 1080i-60 receivers.
[0034] This invention enables 1080i-60 receivers to process the portion of the 1080P-60 program corresponding to a first video stream and reject a complementary second video stream based on PID filtering. Thus, by processing the first video stream, a 1080i-60 receiver provides a portion of the 1080P-60 program that is equivalent to 1080P-30. The invention is equally applicable, for example, to 1080P-50, assigning two separate video streams to a program. Future 1080P50-capable receivers process the 1080P-50 video from the two separate video streams according to the invention, while legacy 1080i-50-capable receivers process a 1080P-25 portion of the 1080P-50 video program.
[0035] Hereinafter, 1080P-60 is used for simplicity to refer to a picture sequence with twice the picture rate of a progressive 1080P-30 picture sequence, or to a picture sequence with twice the amount of picture elements as an interlaced picture sequence displayed as fields rather than full frames. However, it should be understood that the invention is applicable to any pair of video formats with the same picture spatial resolution, in which a first video format has twice the “picture rate” of the second. The invention is also applicable to any pair of video formats with the same picture spatial resolution, in which a first video format has “progressive picture rate” and the second has an “interlaced” or field picture rate, the first video format resulting in twice the number of processed or displayed pixels per second. The invention is further applicable to any two video formats in which the first video format's picture rate is an integer number times that of the second video format or in which the number of pixels of a first video format divided by the number of pixels of a second video format is an integer number.
Stream Types and Unique PIDs
[0036] The MPEG-2 Transport specification referred to in this invention is described in the two documents: ISO/IEC 13818-1:2000 (E), International Standard, Information technology—Generic coding of moving pictures and associated audio information: Systems, and ISO/IEC 13818-1/Amd. 3: 2003 Amendment 3: Transport of AVC video data over ITU-T Rec. H.222.0 |ISO/IEC 13818-1 streams.
[0037] In accordance with MPEG-2 Transport syntax, a multiplexed transport carries Program Specific Information (PSI) that includes the Program Association Table (PAT) and the Program Map Table (PMT). Information required to identify and extract a PMT from the multiplexed transport stream is transmitted in the PAT. The PAT carries the program number and packet identifier (PID) corresponding to each of a plurality of programs, at least one such program's video being transmitted as encoded 1080P-60 video according to the invention.
[0038] As shown in the FIG. 3 , the PMT corresponding to a 1080P-60 program carries two video streams, each uniquely identified by a corresponding PID. The first video stream in the PMT has a unique corresponding PID 341 and the second video stream has its unique corresponding PID 342 , for example. Likewise, the first and second video streams of the 1080P-60 program have corresponding stream type values. A stream type is typically a byte. The stream type value for the first and second video streams are video_type1 and video_type2, respectively.
[0039] In one embodiment, the stream type value, video_type1 equals video_type2, therefore, both video streams are encoded according to the syntax and semantics of the same video specification (e.g., both as MPEG-2 video or as MPEG-4 AVC). A receiver is then able to identify and differentiate between the first video stream and the second video stream by their PID values and the relationship of the two PID values. For example, the lower PID value of video_type1 would be associated with the first video stream. However, legacy HD receivers would not be able to incorporate such a processing step as a feature. However, there may be two types of legacy receivers. During a first era, legacy receivers may be HD receivers that are capable of processing a first video stream encoded according to the MPEG-2 video specification described in ISO/IEC 13818-2:2000 (E), International Standard, Information technology—Generic coding of moving pictures and associated audio information: Video. The second video stream would likely be encoded with a video specification that provides superior compression performance, for example, MPEG-4 AVC as described by the three documents: ISO/IEC 14496-10 (ITU-T H.264), International Standard (2003), Advanced video coding for generic audiovisual services; ISO/IEC 14496-10/Cor. 1: 2004 Technical Corrigendum 1; and ISO/IEC 14496-10/Amd. 1,2004, Advanced Video Coding AMENDMENT 1: AVC fidelity range extensions. A second era, on the other hand, may comprise legacy HD receivers that are capable of processing 1080i-60 video encoded according to the MPEG-4 AVC specification. Because the latter legacy receivers have yet to be deployed, these receivers could be designed to support identification of the first video stream in a multiple video stream program from the lowest PID value corresponding to video_type1 in the PMT. Alternatively, the first video entry in the PMT table, regardless of its PID value, would be considered the first video stream.
[0040] In another alternate embodiment, the streams are encoded according to different video specifications and the values of video_type1 and video_type2 in the PMT differ. For example, the first video stream would be encoded and identified as MPEG-2 video in the PMT by a video_type1 value that corresponds to MPEG-2 video. The second video stream would be encoded with MPEG-4 AVC and identified by a video_type2 value corresponding to MPEG-4 AVC.
[0041] In yet another alternate embodiment, video_type2 corresponds to a stream type specifically designated to specify the complementary video stream (i.e, the second video stream of a 1080P-60 program). Both video streams could be encoded according to the syntax and semantics of the same video specification (e.g, with MPEG-4 AVC) or with different video specifications. Thus, while the values of video_type1 and video_type2 are different in the PMT table for a 1080P-60 program, both video streams composing the 1080P-60 program could adhere to the same video specification. Thus, video_jype 1 's value identifies the video specification used to encode the first video stream, but video_type2's value identifies both:
[0042] (1) the video stream that corresponds to the second video stream of the 1080P-60 program, and
[0043] (2) the video specification (or video coding format) used to encode the second video stream.
[0044] A first video_type2 value then corresponds to a stream type associated with the second stream of a 1080P-60 program that is encoded according to the MPEG-2 video specification. A second video_type2 value corresponds to a stream type associated with the second stream of a 1080P-60 program that is encoded according to the MPEG-4 AVC specification. Likewise, other video_type2 values can correspond to respective stream types, each associated with the second stream of a 1080P-60 program and encoded according to a respective video coding specification.
[0045] In yet another novel aspect of the invention, when video_type2 does not equal video_type1 and their values signify different video specifications, pictures in the second stream can still use reconstructed pictures from the first video stream as reference pictures.
Transmission Order of Pictures
[0046] Encoded pictures in the first and second video streams are multiplexed in the transport multiplex according to a defined sequence that allows a single video decoder in a 1080P-60 receiver to receive and decode the pictures sequentially as if the pictures were transmitted in a single video stream. However, because they are two separate video streams, a 1080i-60 receiver can reject transport packets belonging to the second video stream and allow video packets corresponding to the first video stream to penetrate into its memory to process a portion equal to 1080P-30 video. Encoded pictures in the first video stream are transmitted in transmission order, adhering to the timing requirement and bit-buffer management policies required for a decoder to process the first video stream as a 1080P-30 encoded video signal.
[0047] In one embodiment of the invention, FIG. 4A depicts the first and second video streams in display order. P represents a picture and not a type of picture. Pi is the ith picture in display order. In a 1080P-60 receiver, the blank squares represent gaps of when the picture being displayed is from the complementary video stream. The width of a blank square is one “picture display” time. Non-blank squares represent the time interval in which the corresponding picture is being displayed.
[0048] Still referring to FIG. 4A , in a 1080i-60 receiver, a 1080P-30 picture corresponding to the first video stream is displayed and the width of two squares represents the picture display time. Video stream 1 is specified as 30 Hertz in alternating 60 Hertz intervals that correspond to even integers. Video stream 2 is specified as 30 Hertz in alternating 60 Hertz intervals that correspond to odd integers.
[0049] FIG. 4B depicts pictures according to picture types in display order. Ni signifies the ith Picture in display order, where N is the type of picture designated by the letter I, P or B. In one embodiment, all the pictures in video stream 2 are B pictures and the 1080P-60 receiver uses decoded pictures from video stream 1 as reference pictures to reconstruct the B pictures.
[0050] FIG. 4C corresponds to the transmission order of the pictures in display order in FIG. 4B . Each picture is transmitted (and thus received by the receiver) at least one 60 Hz interval prior to its designated display time. I pictures are displayed six 60 Hz interval after being received and decoded. I pictures are thus transmitted at least seven 60 Hz intervals prior to its corresponding display time. The arrows from FIG. 4C to FIG. 4B reflect the relationship of the pictures' transmission order to their display order.
[0051] Blank squares in FIG. 4C represent gaps when no picture data is transmitted for the respective video stream. The width of a blank square can be approximately one “picture display” time. Non-blank squares represent the time interval in which the corresponding picture is transmitted. One or more smaller transmission gaps of no data transmission may exist within the time interval in which a picture is transmitted. In essence, video stream 1 and video stream 2 are multiplexed at the emission point in a way to effect the transmission order reflected in FIG. 4C and transmission time relationship depicted in FIG. 4C .
Bit-Buffer Management
[0052] A sequence of video pictures is presented at an encoder for compression and production of a compressed 1080P-60 program. Every other picture is referred as an N picture and every subsequent picture as an N+1 picture. The sequence of all the N pictures is the first video stream of the 1080P-60 program and the sequence all the N+1 pictures is the second video stream.
[0053] A video encoder produces the first video stream according to a first video specification (e.g., MPEG-2 video) and the second video stream according to a second video specification (e.g., MPEG-4 AVC). In one embodiment the second video specification is different than the first video specification. In an alternate embodiment, the first and second video specifications are the same (e.g., MPEG-4 AVC).
[0054] The video encoder produces compressed pictures for the first video stream by depositing the compressed pictures into a first bit-buffer in memory, such memory being coupled to the encoder. Depositing of compressed pictures into the first bit-buffer is according to the buffer management policy (or policies) of the first video specification. The first bit-buffer is read for transmission by the video encoder in one embodiment. In an alternate embodiment, a multiplexer or transmitter reads the compressed pictures out of the first bit-buffer. The read potions of the first bit buffer are packetized and transmitted according to a transport stream specifications such as MPEG-2 transport.
[0055] Furthermore, the video encoder, the multiplexer, or the transmitter, or the entity performing the first bit-buffer reading and packetization of the compressed pictures, prepends a first PID to packets belonging to the first video stream. The packetized first video stream is then transmitted via a first transmission channel.
[0056] Similarly, the second video stream is produced by the video encoder and deposited into the first bit buffer. The second video stream is read from the first bit-buffer by the entity performing the packetization, and the entity prepends a second PID to packets belonging to the second video stream, and the transport packets are transmitted via a first transmission channel.
[0057] In an alternate embodiment, the second video stream is produced by the video encoder and deposited into a second bit buffer. The entity performing the packetization reads the second video stream from the second bit buffer and prepends the second PID to packets belonging to the second video stream. The packetized second video stream is then transmitted via a first transmission channel.
[0058] Both first and second video streams are packetized according to a transport stream specification, such as MPEG-2 Transport. Packets belonging to the second video stream are thus identifiable by a 1080P-60 capable receiver and become capable of being rejected by a receiver that is not capable of processing 1080P-60 programs.
[0059] The bit buffer management policies of depositing compressed picture data into the first and/or second bit-buffers and reading (or drawing) compressed-picture data from the first and/or second bit-buffers, are according to the first video specification. These operations may be further in accordance with bit-buffer management policies of the transport stream specification. Furthermore, the bit-buffer management policies implemented on the one or two bit-buffers may be according to the second video specification rather than the first video specification. In one embodiment, the first video stream's compressed data in the bit-buffer is managed according to both: the bit buffer management policies of the first video specification and the transport stream specification, while the second video stream's compressed data in the applicable bit-buffer is managed according to the bit buffer management policies of the second video specification as well as the transport stream specification.
[0060] The bit-buffer management policies described above are applicable at the emission or transmission point in the network, such as by the encoder and the entity producing the multiplexing and/or transmission. Bit-buffer management policies, consistent with the actual implementation at the emission or transmission point, are applicable at the receiver to process the one or more received video streams of a 1080P-60 program. The bit-buffer management policy implemented at the emission or transmission point may be provided to the receiver a priori for each program (e.g., with metadata) or according to an agreed one of the alternatives described above that is employed indefinitely.
[0000] Enabling More than Two Receivers with Different Respective Processing Capabilities
[0061] In an alternate embodiment, the video encoder constitutes two video encoders, a first video encoder producing the first video stream according to the first video specification, and a second video encoder producing the second video stream, which is interspersed for transmission in the transmission channel according to the pockets of “no data” transmission of video stream 1 (as shown in FIG. 4C ). The second video encoder further producing the second video stream according to the second video specification.
[0062] In yet another embodiment, the process of alternating transmission of compressed pictures corresponding to the first video stream and compressed pictures corresponding to the second video stream, results in transmission of a first set of consecutive compressed pictures from different the first video stream when it is the turn to transmit the first video stream, or a second set of consecutive compressed pictures from different the second video stream when it is the turn to transmit the second video stream. For instance, instead of alternating between one compressed picture from the first video stream and one from the second video stream, two consecutive compressed pictures from the second video stream may be transmitted after each transmission of a single compressed picture of the first video stream. Thus, a 1080P-90 Hertz program can be facilitated to 1080P-90 receivers and a 1080P-30 portion of the 1080P-90 program to 1080P-30 receivers. Furthermore, by packetizing every second compressed picture in the second video stream with a third PID value that is different than the first and second PIDs, three corresponding versions of the compressed 1080P-90 program are facilitated respectively to a 1080P-30 receiver, a 1080P-60 receiver, and a 1080P-90 receiver, the latter being able to receive and fulfill the full benefits of the 1080P-90 program.
[0063] In yet another embodiment, the number of consecutive compressed pictures that is transmitted from the first video stream may be grater than one. For instance, if two consecutive compressed pictures from the first video stream are transmitted and three compressed pictures from the second video stream are transmitted after transmission the two from the first video stream, a number of receivers with different processing capabilities may be enabled. If two different PID values are employed, a 1080P-50 receiver will receive a 1080P-50 Program and a 1080P-20 receiver will receive a 1080P-20 corresponding portion. However, if five different PID values are used for the 1080P-50 program, five receivers, each with different processing capability will be capable of receiving a portion of the 1080P-50 program.
Third Video Specification
[0064] Headend 110 may receive from an interface to a different environment, such as from a satellite or a storage device, an already compressed 1080P-60 program—a single video stream encoded according to a third video specification and according to a first stream specification. The first stream specification may be a type of transport stream specification suitable for transmission or a type of program stream specification suitable for storage. The third video specification may comprise of the first video specification, the second video specification, or both the first and second video specifications respectively applied, for example, to every other compressed picture. However, the already compressed 1080P-60 program is received at headend 110 encoded in such a way that it does not facilitate reception some of its portions by receivers with processing capability that are less than those of a 1080P-60 receiver. In other words, it is received without information to inherent signal its different portions to receivers with different processing capabilities.
[0065] Another novel aspect of this invention is that at least one from one or more encoders, one or more multiplexers, or one or more processing entities at the point of transmission at headend 110 , effect packetization of the compressed pictures of the received 1080P-60 program with a plurality of different PIDS, then transmitting the 1080P-60 program as a plurality of identifiable video streams via the first transmission channel. Thus, headend 110 effects proper packetization and prepending of PID values to enable reception of at least a portion of the 1080P-program to receivers with different processing capabilities that are coupled to network 130 .
[0066] The present invention includes methods and systems capable of transmitting compressed video signals according to one or more compression video formats, where compressed video signals correspond to television channels or television programs in any of a plurality of picture formats (i.e., picture spatial resolution and picture rate), including 1080i-60 and 1080P-60 formats. The compressed video signals which correspond to television channels or television programs in any of a plurality of picture formats are received by a plurality of receivers, where each receiver may have a different maximum processing capability. Therefore, the present invention contemplates at least the following combinations for encoding, transmission and reception of video signals. In the following combinations of trio “input/receiver/display,” the input, such as 1080P-60 input in the first combination instance, refers to a compressed video stream that is received at receiver 200 from network 130 via communication interface 242 . The display, such as the 1080P-60 Display in the first combination instance is a television, a display, or a monitor coupled to DHCT 200 via output system 248 . The DHCT 200 provides the compressed video stream corresponding to the “input” in “decoded and reconstructed” form (visible pictures) via output system 248 . The receiver, such as 1080P-60 Receiver in the first combination instance, refers to a receiver, such as DHCT 200 , that has the processing capability specified in the trio.
1080P-60 Input/1080P-60 Receiver/1080P-60 Display
[0067] In order to process a 1080P-60 compressed video signal, a 1080P-60 capable receiver receives a compressed 1080P-60 video stream via a network interface (or a communication interface). The 1080P-60 compressed video signal is input by storing it in its memory and the receiver decodes with a video decoder (or decompression engine) all the pictures corresponding to the 1080P-60 video signal (or compressed video stream). A 1080P-60 capable display is driven by all the decoded 1080P-60 pictures.
[0000] 1080i-60 Input/1080P-60 Receiver/1080P-60 Display
[0068] In order to process a 1080i-60 compressed video signal, the 1080P-60 capable receiver receives a compressed 1080i-60 video stream via a network interface (or a communication interface). The 1080P-60 compressed video signal is input by storing it in its memory and the receiver decodes with a video decoder (or decompression engine) all the pictures corresponding to the compressed 1080i-60 video signal stored in memory. The 1080P-60 receiver then deinterlaces the decoded 1080i-60 signal with a de-interlacing algorithm based on information in two or more 1080i fields, including a current 1080i field. The deinterlacing algorithm makes decisions based on spatial picture information as well as temporal information. The deinterlacing algorithm can further base decisions on motion estimation or motion detection. A 1080P-60 capable display is driven by all the decoded 1080P-60 pictures.
1080P-60 Input/1080P-60 Receiver/Non-1080P-60 Display
[0069] In order to process a 1080P-60 compressed video signal, the 1080P-60 capable receiver receives a compressed 1080P-60 video stream via a network interface (or a communication interface). When driving a non-1080P-60 display, the receiver outputs a portion of all the decoded 1080P-60 pictures or processes and scales the pictures of the decoded 1080P-60 signal for display. When driving a non-1080P-60 display such as a 1080i-60 display, the 1080P-60 capable receiver could process a 1080P-60 compressed video signal in full (as explained above) and output (or display) a portion of each of the decoded 1080P-60 pictures. The portion may be a temporally-subsampled portion, a spatially-subsampled portion, or a portion resulting from a combination of a temporal-subsampling and spatially-subsampling. Alternatively, when driving a non-1080P-60 capable display, the 1080P60-capable receiver is informed by the user or through a discovery mechanism that the display is not 1080P-60. Consequently, the 1080P-60-capable receiver can behave as if it was a 1080P-30 receiver by not processing the second video stream.
[0000] 1080i-60 Input/1080P-60 Receiver/Non-1080P-60 Display
[0070] When driving a non-1080P-60 display, a 1080P-60 receiver processes a 1080i-60 compressed video signal and outputs the decoded 1080i-60 pictures according to the picture format required to drive the non-1080 display, processing and scaling the pictures of the decoded 1080i-60 signal as required to drive the non-1080P-60 display.
[0000] 1080P-60 Input/1080i-60 Receiver/Non-1080P-60 Display
[0071] In order to process a 1080P-60 compressed video signal, a 1080i-60 capable receiver receives a compressed 1080P-60 video stream via a network interface (or a communication interface). The receiver inputs a first portion of the 1080P-60 compressed video signal by storing it in memory of receiver 200 and the receiver rejects a second and complementary portion of the 1080P compressed video signal by prohibiting it from penetrating any section, portion or buffer of its memory. The receiver 200 decodes with a video decoder (or decompression engine) all the pictures corresponding to the first portion of the 1080P-60 video signal; processing it as if it were a 1080i-60 compressed video signal. A 1080i-60 capable display is driven by the decoded first portion of the 1080P-60 pictures.
[0000] 1080P-60 Input/1080i-60 Receiver/1080P-60 Display—A
[0072] In order to process a 1080P-60 compressed video signal, a 1080i-60 capable receiver receives a compressed 1080P-60 video stream via a network interface (or a communication interface). The receiver inputs a first portion of the 1080P-60 compressed video signal corresponding to a 1080i-60 compressed video signal by storing it in its memory and rejects a second and complementary portion of the 1080P compressed video signal by prohibiting it from penetrating any section, portion or buffer of its memory. The receiver decodes with a video decoder (or decompression engine) all the pictures corresponding to the first portion of the 1080P-60 video signal, processing it as if it were a 1080i-60 compressed video signal. The receiver deinterlaces a decoded 1080i-60 signal with a deinterlacing algorithm based on information in two or more 1080i fields, including a current 1080i field. The deinterlacing algorithm makes decisions based on spatial picture information as well as temporal information. The deinterlacing algorithm can further base decisions on motion estimation or motion detection. A 1080P-60 capable display is driven by all the decoded and deinterlaced 1080i-60 pictures as a 1080P-60 signal.
[0000] 1080P-60 Input/1080i-60 Receiver/1080P-60 Display—B
[0073] In order to process a 1080P-60 compressed video signal, a 1080i-60 capable receiver receives a compressed 1080P-60 video stream via a network interface (or a communication interface). The receiver inputs a first portion of the 1080P-60 compressed video signal corresponding to a 1080i-60 compressed video signal by storing it in its memory and rejects a second and complementary portion of the 1080P-60 compressed video signal by prohibiting it from penetrating any section, portion or buffer of its memory. The receiver decodes with a video decoder (or decompression engine) all the pictures corresponding to the first portion of the 1080P-60 video signal, processing it as if it were a 1080i-60 compressed video signal. In order to drive a 1080P-60 capable display that is capable of receiving a 1080i-60 signal and internal deinterlacing, the display is driven by all the pictures of the decoded 1080i-60 compressed video signal as a 1080i-60 signal. The 1080P-60 display deinterlaces the received 1080i-60 signals according to its deinterlacing capabilities.
Encoding and Transmission
[0074] The encoder produces a 1080P-60 encoded video stream according to a video specification (i.e., MPEG-2 video or MPEG-4 AVC), and assigns a first PID value to packets of every other encoded picture corresponding to the 1080P-60, and assigns a second PID value to every packet of the subsequent picture to the “every other” picture just mentioned, where the second PID value is different from the first PID value. Denoting “every other picture” by N, every subsequent picture is then N+1; and the first PID_value is used for N, while the second PID_value is used for N+1.
[0075] The encoder in one embodiment encodes all pictures according to a single video format, e.g., MPEG-4 AVC, and adheres to the buffer model of the video specification. The encoder in a second embodiment encodes the pictures that correspond to N according to a first video specification and in compliance with the video specification's buffering model, and according to a variable-bit rate model. The encoder further encodes the alternate pictures, every “N+1” picture, according to a second video specification, the second video specification being different from the first video specification. These alternate pictures are encoded according to the syntax of the second video specification, but managed and transferred into a transmission buffer according to the first video specification's buffering model. The encoder further employs in its “encoding loop” a model, or parts thereof, of a receiver's video decoder, including reference pictures, in it's memory.
[0076] Encode 1080P at 60 frames per second, into a single output, ensuring that every other picture (in both decode order and presentation order) is a non-reference picture. Every picture encoded is a progressive frame representing 1/60 th seconds. Now, every other picture can be separated into a new PID. This new PID may be called “PID B”, and the other PID may be called “PID A”. PID B contains only non-reference pictures that can optionally be included in the decoding of PID A. In this separation process, the original picture ordering must be maintained within the multiplex. For example, a picture in one PID must end before the next picture begins in the other PID.
[0077] For backwards-compatibility, the frame rate value in PID A should be set at 30 frames per second; and the temporal references in PID A should be corrected for the separated pictures; and as a convenience, the temporal references in PID B should be set to match those in PID A, such that each picture pair shares a temporal reference number. The 1080P-60 capable decoder will be aware that the frame rate is actually 60 frames per second, and will support the pairs of duplicate temporal references. When decoding both PID A and PID B in combination, the decoder should expect two of every temporal reference number, adjacent in presentation order. Therefore, for example, it can use the temporal reference numbers to detect a missing picture. Picture re-ordering within the decoder may be based on the sequence of picture types received, as normal.
[0078] The following are examples of this scheme demonstrating how a decoder could receive PID A alone, or receive the combination of PID A and PID B. In these examples, the “B”-type pictures represent non-reference frames. Also, these examples are given in decode order, and the numbers represent temporal references (indicating presentation order).
[0000] Example 1, IBBBP . . . : Before temporal reference number (TRN) correction: PID A: I3_B1_P7_B5_P11_B9_P15_B13 — PID B: _B0_B2_B4_B6_B8_B10_B12_B14 After TRN correction: PID A: I1_B0_P3_B2_P5_B4_P7_B6 — PID B: _B0_B1_B2_B3_B4_B5_B6_B7 Example 2, IBP . . . : Before TRN correction: PID A: I1_P3_P5_P7_P9_P11_P13_P15 — PID B: _B0_B2_B4_B6_B8_B10_B12_B14 After TRN correction: PID A: I0_P1_P2_P3_P4_P5_P6_P7 — PID B: _B0_B1_B2_B3_B4_B5_B6_B7
In the PMT, PID B can be designated by a new stream_type. A common set of audio streams may serve each case: 1) using only PID A 2) using both PID A and PID B.
[0079] In the above described method of encoding and transmission, the separation of every other frame occurred after encoding. In an alternative embodiment, separation occurs prior to encoding. At one encoder's input, supply every other frame of a 1080P-60 hz signal. Encode this as 1080P-30 hz. Simultaneously, supply another encoding process with the alternate frames, also at 1080P-30 hz. Presentation time stamps (PTSs) shall be generated for every picture, referencing a common clock. The result is two video streams, each being legitimate 1080P-30 hz. A 1080P-60 capable decoder may decode both simultaneously, as a dual-decode operation, to be recombined in the display process. There need be no further correlation between the two PIDs than the commonly referenced PTSs. For example, the group of pictures (GOP) structures, as defined by the video specification (e.g., MPEG-2 video GOP) may be independent, and the buffering may be independent. To recombine the dual 1080P-30 streams into a single 1080P-60 output, the dual-decoder's display process will choose decoded pictures to put on display in order of PTS. If the picture for a particular time interval has not yet been decoded, possibly due to some data corruption or loss, then the previous picture will simply be repeated through that time interval. If any picture is decoded later than its PTS elapses, it is to be discarded. Even though both PIDs may be completely independent, because they reference the same clock, there is no risk that a picture from one PID is sent later than the presentation time of a following picture from the other PID, as long as each PID's buffer is maintained compliantly within the multiplex.
[0080] PID B in the PMT may be designated by a new stream_type, which may be allocated by MPEG, or which may be a user-private stream_type that indicates a privately managed stream. The new stream_type would not be recognized by legacy receivers, so the associated PID B would be ignored. As an additional method of unambiguous identification of the special second PID, the registration_descriptor may be used in the ES_descriptor_loop of the PMT to register a unique and private attribute for association with PID B. Any combination of the above methods may be used, as deemed adequate and sensible. A common set of audio streams may serve each case: 1) using only PID A 2) using both PID A and PID B. The methods described above use a separate PID to carry additional information. In those cases, the separate PID can optionally be ignored by the decoder. In another alternative embodiment, a single video PID may be used to carry both the base information and the additional information, while still providing a way to optionally reject the additional information. A separate packetized elementary stream (PES) ID can be used such that a new PMT descriptor, which would be allocated by MPEG, may designate one PES ID for the base layer, and a different PES ID for the additional information, both carried by the same PID. In this way, existing PES IDs may be identified as base, and supplemental, without the need for new PES IDs to be allocated. The decoder that needs only the base layer may discard those PES packets whose ID does not match the ID designated as the base layer in the PMT. The decoder that can use both may simply not reject either. This approach is applicable to both schemes: post-encoding-separation and prior-encoding-separation.
[0081] The foregoing has broadly outlined some of the more pertinent aspects and features of the present invention. These should be construed to be merely illustrative of some of the more prominent features and applications of the invention. Other beneficial results can be obtained by applying the disclosed information in a different manner or by modifying the disclosed embodiments. Accordingly, other aspects and a more comprehensive understanding of the invention may be obtained by referring to the detailed description of the exemplary embodiments taken in conjunction with the accompanying drawings, in addition to the scope of the invention defined by the claims. | Methods and systems for the efficient and non-redundant transmission of a single video program in multiple frame rates, optionally employing a combination of video coding standards, in a way that is backwards-compatible with legacy receivers only supportive of some subsection of frame rates or of some subsection of video coding standards. | 57,035 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present patent application is a US National Stage of International Application No. PCT/CA2013/000884, filed on Oct. 15, 2013, which claims priority under 35 USC §119(e) of U.S. provisional Application Ser. No. 61/713,226, filed on Oct. 12, 2012, the contents of which are hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to methods for evaluating scoliosis prognosis. In particular, the present invention relates to methods and systems for predicting the progression of scoliosis, stratifying a subject having a scoliosis and assessing the efficacy of a brace on a subject having a scoliosis.
BACKGROUND
Spinal deformities and scoliosis in particular, represent the most prevalent type of orthopedic deformities in children and adolescents. Adolescent idiopathic scoliosis (AIS) is a three-dimensional spinal deformity with a prevalence of 1.34% in children between 6 and 17 years old for a Cobb angle of 10° or more.
Classical risk factors such as skeletal maturity, initial Cobb angle and type of curvature were found to predict final Cobb angle but to a certain extent only. There is still no reliable method to predict whether an individual's curve will progress and how severe the progression will be. Current treatments are only available to patients with a curvature>25°.
The only treatment available today for patients with a moderate curvature (<40° but >25°) is external bracing. Bracing never corrects a curve but rather stabilizes the curve during the time an adolescent is growing, although its effectiveness is questionable (50% of those wearing a brace simply do not benefit). It has also been shown that bracing typically proves ineffective on two (2) patients out of three (3). For patients with a curvature >40°, the current option is the surgical correction.
Unfortunately, there is no proven method available to identify which affected children or adolescents may require treatment based on the risk of progression. Consequently, the application of current treatments is delayed until a significant deformity is detected or until a significant progression is clearly demonstrated, resulting in a delayed and less optimal treatment. Also, the uncertainty related to curve progression and outcome creates anxiety for families and patients with scoliosis as well as unnecessary psychosocial stresses associated with brace treatment. The failure to accurately predict the risk of progression can also lead to inadequate treatment, as well as unnecessary medical visits and radiographs.
There is thus a need for a method of predicting the scoliosis curve progression, particularly in treatment decisions for individuals who are diagnosed with scoliosis.
SUMMARY
There is described herein a method and system for predicting scoliosis curve progression based on measuring a combination of predictive factors. A predictive model is created based on type of curvature, skeletal maturity and three-dimensional (3D) spine parameters. The predictive model may thus enable early prognosis of scoliosis, stratifying of subjects having a scoliosis as well as early clinical intervention to mitigate progression of the disease. It may also allow selection of subjects for clinical trials involving less invasive treatment methods.
The 3D spine parameters are selected from one or more of the six categories of 3D measurements or parameters: angle of plane of maximum curvature, initial Cobb angles (kyphosis, lordosis), 3D wedging (apical vertebra, apical disks), rotation (upper and lower junctional vertebra, apical vertebra, thoracolumbar junction and mean peri-apical intervertebral) rotation, torsion (geometrical and/or mechanical torsion) and slenderness (height/width ratio).
In accordance with a broad aspect, there is provided a system for generating a final Cobb angle prediction for idiopathic scoliosis, the system comprising a memory having stored thereon a predictive model based on 3D morphological spine parameters, curve type, and skeletal maturity; a processor; and at least one application stored in the memory and executable by the processor for receiving patient-specific 3D morphological spine parameters, a selected curve type, and a selected skeletal maturity, retrieving the predictive model, and modeling a progression curve of the idiopathic scoliosis to generate the final Cobb angle prediction.
In some embodiments, the at least one application is further configured to receive two-dimensional spine data, reconstruct a three-dimensional spine morphology, and extract the patient-specific 3D morphological spine parameters therefrom.
In some embodiments, the patient-specific 3D morphological spine parameters comprise at least one of an initial Cobb angle, a plane of maximal deformation, a three-dimensional wedging of vertebral body and disk, an axial intervertebral rotation of an apex, upper and lower junctional level and thoracolumbar level, slenderness, and torsion.
In some embodiments, the at least one application is executable by the processor for computing the initial Cobb angle in at least one of a frontal plane of the reconstructed three-dimensional spine morphology, a sagittal plane of the reconstructed three-dimensional spine morphology, and the plane of maximal deformation.
In some embodiments, the at least one application is executable by the processor for applying the patient-specific 3D morphological spine parameters, the selected curve type, and the selected skeletal maturity to the retrieved predictive model for modeling the progression curve from the initial Cobb angle to a predicted final Cobb angle, the predicted final Cobb angle indicative of a forecasted evolution of the idiopathic scoliosis at the selected skeletal maturity.
In some embodiments, the at least one application is executable by the processor for computing the plane of maximal deformation as a plane in the reconstructed three-dimensional spine morphology having an axial angle that extends around a direction in which the initial Cobb angle is maximal.
In some embodiments, the at least one application is executable by the processor for computing three-dimensional wedging of junctional and peri-apical disk levels of the reconstructed three-dimensional spine morphology, and a sum of three-dimensional wedging of all thoracic and lumbar disks of the reconstructed three-dimensional spine morphology.
In some embodiments, the at least one application is executable by the processor for computing the axial intervertebral rotation of a superior vertebra of the reconstructed three-dimensional spine morphology relative to an inferior vertebra of the reconstructed three-dimensional spine morphology, the inferior vertebra adjacent the superior vertebra and the superior and inferior vertebrae each having defined therefor in the reconstructed three-dimensional spine morphology a local axis plane comprising a first axis, the rotation computed by projecting the first axis of the superior vertebra onto the local axis plane of the inferior vertebra.
In some embodiments, the at least one application is executable by the processor for computing the slenderness as a ratio of a height to a width of a body of each one of thoracic and lumbar vertebrae of the reconstructed three-dimensional spine morphology.
In some embodiments, the at least one application is executable by the processor for receiving the patient-specific 3D morphological spine parameters comprising at least one of a mechanical torsion and a geometrical torsion.
In some embodiments, the at least one application is executable by the processor for calculating the mechanical torsion by computing a first sum of the axial intervertebral rotation for all vertebrae in a first hemicurvature of a main idiopathic scoliosis curve in the reconstructed three-dimensional spine morphology, a second sum of the axial intervertebral rotation for all vertebrae in a second hemicurvature of the main curve, and a mean of the first sum and the second sum, the first hemicurvature defined between an upper end vertebra and an apex of the main curve and the second hemicurvature defined between a lower end vertebra of the main curve and the apex.
In some embodiments, the at least one application is executable by the processor for receiving the selected curve type comprising one of single right thoracic, double with main thoracic, double with main lumbar, triple, single left thoracolumbar, single left lumbar, and left thoracic-right lumbar.
In some embodiments, the at least one application is executable by the processor for receiving the selected skeletal maturity comprising skeletal maturity data indicative of one of a first stage skeletal maturity and a second stage skeletal maturity, the first stage skeletal maturity characterized by an open triradiate cartilage with a Risser grade equal to zero and the second stage skeletal maturity characterized by one of a Risser grade equal to one and a closed triradiate cartilage with a Risser grade equal to zero.
In some embodiments, the memory has stored therein a plurality of treatment options each suitable for treating the idiopathic scoliosis and having associated therewith at least one of a range of final Cobb angles and a rate of change of idiopathic scoliosis curve progression, and further wherein the at least one application is executable by the processor for querying the memory with at least one of the final Cobb angle prediction and the modelled progression curve to retrieve a selected one of the plurality of treatment options and for outputting the final Cobb angle prediction and the selected treatment option.
In some embodiments, the memory has stored thereon the predictive model comprising a general linear statistical model associating the final Cobb angle prediction with selected predictors, the selected predictors comprising the 3D morphological spine parameters, curve type, and skeletal maturity and determined by a backward selection procedure.
In accordance with another broad aspect, there is provided a computer-implemented method for generating a final Cobb angle prediction for idiopathic scoliosis, the method comprising receiving patient-specific 3D morphological spine parameters, a selected curve type, and a selected skeletal maturity; applying the patient-specific 3D morphological spine parameters, a selected curve type, and a selected skeletal maturity to a predictive model based on 3D morphological spine parameters, curve type, and skeletal maturity, and generating the final Cobb angle prediction by modeling a progression curve of the idiopathic scoliosis.
In some embodiments, the method further comprises receiving two-dimensional spine data, reconstructing a three-dimensional spine morphology, and extracting the patient-specific 3D morphological spine parameters therefrom.
In some embodiments, receiving the patient-specific 3D morphological spine parameters comprises receiving at least one of an initial Cobb angle, a plane of maximal deformation, a three-dimensional wedging of vertebral body and disk, an axial intervertebral rotation of an apex, upper and lower junctional level and thoracolumbar level, slenderness, and torsion.
In some embodiments, receiving the patient-specific 3D morphological spine parameters comprises receiving the initial Cobb angle computed in at least one of a frontal plane of the reconstructed three-dimensional spine morphology, a sagittal plane of the reconstructed three-dimensional spine morphology, and the plane of maximal deformation.
In some embodiments, receiving the patient-specific 3D morphological spine parameters comprises receiving the plane of maximal deformation as a plane in the reconstructed three-dimensional spine morphology having an axial angle that extends around a direction in which the initial Cobb angle is maximal.
In some embodiments, receiving the patient-specific 3D spine parameters comprises receiving three-dimensional wedging of junctional and peri-apical disk levels of the reconstructed three-dimensional spine morphology and a sum of three-dimensional wedging of all thoracic and lumbar disks of the reconstructed three-dimensional spine morphology.
In some embodiments, receiving the patient-specific 3D morphological spine parameters comprises receiving the axial intervertebral rotation computed for a superior vertebra of the reconstructed three-dimensional spine morphology relative to an inferior vertebra of the reconstructed three-dimensional spine morphology, the inferior vertebra adjacent the superior vertebra and the superior and inferior vertebrae each having defined therefor in the reconstructed three-dimensional spine morphology a local axis plane comprising a first axis, the rotation computed by projecting the first axis of the superior vertebra onto the local axis plane of the inferior vertebra.
In some embodiments, receiving the patient-specific 3D morphological spine parameters comprises receiving the slenderness computed as a ratio of a height to a width of a body of each one of thoracic and lumbar vertebrae of the reconstructed three-dimensional spine morphology.
In some embodiments, receiving the patient-specific 3D morphological spine parameters comprises receiving the torsion obtained by computing a first sum of the axial intervertebral rotation for all vertebrae in a first hemicurvature of a main idiopathic scoliosis curve in the reconstructed three-dimensional spine morphology, a second sum of the axial intervertebral rotation for all vertebrae in a second hemicurvature of the main curve, and a mean of the first sum and the second sum, the first hemicurvature defined between an upper end vertebra and an apex of the main curve and the second hemicurvature defined between a lower end vertebra of the main curve and the apex.
In some embodiments, the method further comprises querying a memory with at least one of the generated final Cobb angle prediction and the modelled progression curve to retrieve a selected one of a plurality of treatment options stored in the memory, each of the plurality of treatment options suitable for treating the idiopathic scoliosis and having associated therewith at least one of a range of final Cobb angles and a rate of change of idiopathic scoliosis curve progression, and outputting the final Cobb angle prediction and the selected treatment option.
In accordance with yet another broad aspect, there is provided a computer readable medium having stored thereon program code executable by a processor generating a final Cobb angle prediction for idiopathic scoliosis, the program code executable for receiving patient-specific 3D morphological spine parameters, a selected curve type, and a selected skeletal maturity; applying the patient-specific 3D morphological spine parameters, a selected curve type, and a selected skeletal maturity to a predictive model based on 3D morphological spine parameters, curve type, and skeletal maturity, and generating the final Cobb angle prediction by modeling a progression curve of the idiopathic scoliosis.
This technique of predicting scoliosis curve progression may help monitor patients with AIS and help tailor their treatment plan accordingly.
For the present specification, “Cobb angle” refers to a measure of the curvature of the spine, determined from measurements made on X-ray photographs. Specifically, scoliosis is defined by the Cobb angle. The Cobb angle is illustratively computed as the angle formed between a line drawn parallel (or perpendicular) to the superior endplate of the uppermost vertebra involved in the AIS deformity a line drawn parallel (or perpendicular) to the inferior endplate of the lowermost vertebra involved. A lateral and rotational spinal curvature of the spine with a Cobb angle of >10° is defined as scoliosis. “Risser sign” refers to a measurement of skeletal maturity. Skeletal maturity can be divided into three sequential stages: 1) Risser 0 with open triradiate cartilage, 2) Risser 0 with closed triradiate cartilage or Risser 1, and 3) Risser 2 or greater. The second stage correlates with the rapid acceleration phase. More precisely, a Risser sign is defined by the amount of calcification present in the iliac apophysis, divided into quartiles, and measures the progressive ossification from anterolaterally to posteromedially. A Risser grade of 1 signifies up to 25 percent ossification of the iliac apophysis, proceeding to grade 4, which signifies 100 percent ossification. A Risser grade of 5 means the iliac apophysis has fused to the iliac crest after 100 percent ossification. Children usually progress from a Risser grade 1 to a grade 5 over a two-year period during the most rapid skeletal growth.
Many other uses and advantages of the present invention will be apparent to those skilled in the art upon review of the detailed description herein. Solely for clarity of discussion, the invention is described in the sections below by way of non-limiting examples.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a 3D reconstruction of a scoliotic spine with plane of maximal deformity represented by a triangle for each curvature (thoracic proximal curve, main thoracic and lumbar) in the axis system with <<x>> axis anterior, <<y>> axis left and <<z>> axis cephalad;
FIG. 2A illustrates the Vertebral body 3D wedging;
FIG. 2B is an illustration of the mean of the two apical 3D disks wedging;
FIG. 3A is an illustration of intervertebral rotation;
FIG. 3B in an illustration of slenderness with height/width (h/w) ratio of a single vertebral body;
FIG. 4 is an illustration of torsion. χ (mean) Σ (sum) θ (angle);
FIG. 5 is a flowchart of an exemplary method for creating a predictive model for AIS;
FIG. 6 represents the frequency histogram with final Cobb angle on <<x>> axis and frequency on <<y>> axis with a normal curve illustrated;
FIG. 7 is a block diagram of an exemplary system for predictive modeling of AIS;
FIG. 8 is a block diagram of an exemplary system for the predictive model system of FIG. 7 ; and
FIG. 9 is a block diagram of an exemplary application running on the predictive model system of FIG. 8 .
DETAILED DESCRIPTION
There is described a method and system for predicting final Cobb angle in idiopathic scoliosis based on information available at a first visit. In one embodiment, the method and system apply to AIS, as described herein. It should however be understood that other types of scoliosis, such as early onset idiopathic scoliosis, may also apply. A plane of maximal curvature is provided as a risk factor of progression. One or more of the following predictive factors are combined in order to obtain the predictive model: type of curvature, skeletal maturity, initial Cobb angle, angle of plane of maximal curvature, 3D wedging of junctional and peri-apical disks (e.g. T3-T4, T8-T9, T11-T12 disks) and sum of thoracic and lumbar 3D disks wedging.
Classical risk factors such as skeletal maturity, initial Cobb angle and type of curvature are found to predict final Cobb angle to a certain extent. The addition of the plane of maximal curvature as well as the sum of the disk wedging of the thoracic and lumbar levels and three specific 3D junctional and peri-apical disks wedging levels (e.g. T3-T4, T8-T9, T11-T12) improves the overall prediction of the final Cobb angle.
A study was performed with the objective of developing a predictive model of the final Cobb angle in adolescent idiopathic scoliosis based on 3D spine parameters. A prospective cohort was recruited in a single center from January 2006 to May 2010. The inclusion criteria were (1) first visit with an orthopedic surgeon with a diagnosis of AIS, (2) Cobb angle between 11 and 40 degrees, and (3) Risser sign of 0 or 1. The exclusion criteria were (1) congenital, neuromuscular or syndromic scoliosis. Patients with a Risser sign of 2 or greater were also excluded. Curves greater than 40 degrees were also excluded because they fall into a category in which some surgeons will consider a fusion surgery.
At the first and for all subsequent visits, each patient had a lateral and PA spine radiographs. Patients were followed by one of four (4) spine surgeons with intervals of follow up chosen by treating surgeon. The endpoint for the study occurred when patients reached skeletal maturity (at least Risser 4) or when a fusion surgery was performed. Brace treatment was allowed according to the treating physician, but brace had to be removed the night before appointment.
For all patients, the curve type was defined either as a single right thoracic, double with main thoracic, double with main lumbar, triple, single left thoracolumbar, single left lumbar or other (left thoracic and right lumbar). The Risser sign and triradiate cartilage status (open or closed) was evaluated at the first visit. The skeletal maturity status was set as either stage 0 (open triradiate cartilage and Risser 0) or stage 1 (Risser 0 with closed triradiate cartilage or Risser 1).
All patients had a 3D spinal reconstruction of the spine at the first visit from the PA and lateral radiographs. Reconstructions were done with two softwares: Spine 3D (LIS3D, Montreal, Canada) and IdefX (LIO, Montreal, Canada), by one research assistant expert in the technique. Two different softwares were used in order to conform with the specifications proper to each of the two radiographic imaging systems used in the current study: Spine 3D was used with the Fuji system (58 first patients of the cohort) and IdefX was used with the EOS™ system (75 last patients of the cohort). The Spine 3D software uses algorithms based on direct linear transformation combined with the Non Stereo Corresponding Points algorithm (NSCP); this is based on identification of corresponding anatomical landmarks on vertebrae from stereo-radiographs. IdefX software uses a semi-automated (SA) method based on a priori knowledge. Both softwares generated 3D reconstructions of comparable accuracy. There is no difference in terms of mean errors between 3D vertebral models obtained from stereo-radiography (NSCP and SA) and CT-scan reconstructions. The precision of these reconstructions has been shown to be very satisfactory with mean point-to-surface errors of less than 1.5 mm and less than two degrees for angular measurements when compared to conventional CT-Scan reconstructions.
All measurements were computerized 3D radiologic measurements done with the same custom software IdefX (LIO, Montreal, Canada) for all reconstructions.
The calculated 3D parameters were illustratively divided in six (6) categories consisting of global (whole spine), regional (scoliotic segment) or local (vertebra) descriptors. The centroid of each vertebra is defined as the point half way between the center of the upper and lower endplates of the vertebra. The global axis system is defined by the SRS 3D terminology group as follows: the origin is at the center of the upper endplate of S1, the <<z>> axis is vertical (gravity line) and the <<y>> axis is between the anterior superior iliac spine and pointing to the left. The local vertebra axis system is defined by the SRS 3D terminology group as follows: the origin is at the centroid of the vertebral body, the local ‘z’ axis passes through the centers of the upper and lower endplates and pointing in a cephalad direction, and ‘y’ axis is parallel to a line joining similar landmarks on the bases of the right and left pedicles pointing to the left. An exemplary set of the 3D parameters for each parameter category is as follows. It should be understood that each parameter category may comprise several 3D parameters.
1—Cobb Angles: Cobb angles were defined as the angle between the upper and lower end plate of the respective end vertebrae of a curve. Cobb angle was measured in the frontal plane, in the plane of maximal deformation in 3D and in the sagittal plane for thoracic kyphosis (T4-T12) and lumbar lordosis (L1-L5).
2—Plane of maximal deformation: Referring now to FIG. 1 , there is illustrated a plane 102 of maximal deformation. The axial angle (not shown) of the plane 102 is around a direction, e.g. a global z-axis, in which the Cobb angle is maximal. The plane 102 of maximal deformation is illustratively represented by a triangle 104 1 , 104 2 , 104 3 for each curvature in the spine 106 , e.g. for the thoracic proximal curve, main thoracic curvature, and lumbar curvature, respectively.
3—Three-dimensional wedging of vertebral body and disk: FIGS. 2 a and 2 b illustrate three-dimensional wedging θ 3D of vertebral body and disk. Wedging of the apical vertebral body 202 in the plane 102 of maximal deformation (3D plane) and mean maximal 3D wedging of the two apical intervertebral disks as in 204 1 , 204 2 are shown. Maximal 3D wedging represents the wedging measured in the plane, wherein the wedging value is maximal around the vertical axis. If the apex was a disk (see FIG. 2 b ), then the mean of the 3D wedging θ 1 3D , θ 2 3D of both apical vertebral bodies was calculated and only the 3D wedging of the apical disk was reported instead of the mean of two apical disks. 3D disk wedging was analyzed for all levels of the thoracic and lumbar spine (from T1-T2 to L4-L5).
4—Axial intervertebral rotation of the apex, upper and lower junctional level and thoracolumbar level: This is shown in FIG. 3 a . In particular, rotation between two adjacent vertebrae 302 1 , 302 2 at upper, apical and lower curve level and thoracolumbar junction (T12-L1) with reference to the local axis system of the inferior vertebra 302 2 are illustrated. The rotation θ AXIAL of the superior vertebra 302 1 with respect to the inferior vertebra 302 2 was calculated after projecting the local x-axis of the superior vertebra 302 1 into the x-y plane of the local axis system of the inferior vertebra 302 2 . The definition of the SRS 3D terminology group for the intervertebral rotation is the projected angles between the local axis of two adjacent vertebrae.
5—Slenderness: FIG. 3 b illustrates slenderness (local T6, T12 and L4 and regional T1-L5), or the ratio between the height h (distance between the superior and inferior end plates at the center of the vertebrae) and the width w (measured at the center of the vertebrae using a line perpendicular to the height line in medio-lateral direction) of the vertebral body for T6, T12 and L4 vertebrae. Ratio may also be found between the length of the spine between T1 and L5 and the mean of the width of vertebral bodies of T6, T12 and L4. The same calculations were made with the width being replaced by the depth (a line perpendicular to the height line at the center of the vertebra in the anteroposterior direction). The length between T1-L5 is the length of a line starting at the center of the upper endplate of T1, passing through the centroid of all vertebrae down to the center of the lower endplate of L5. The line was smoothed using a cubic spline function. T6 and L4 were selected and T12 was added as a thoracolumbar landmark. It should however be understood that slenderness calculation is not limited to T6, T12, and L4 vertebrae and may apply to any thoracic or lumbar vertebra.
6—Torsion: FIG. 4 illustrates mechanical torsion, or the mean of the sum of intervertebral axial rotation (measured according to the local referential of the inferior vertebrae) for all vertebrae included in the two hemicurvatures (between upper end vertebra and apex and between lower end vertebra and apex, not shown) of the main scoliotic curve 402 of the spine 106 . For this purpose, a first sum Σθ AXIAL1 of intervertebral axial rotation for all vertebrae in the first hemicurvature (not shown) is computed. A second sum Σθ AXIAL2 of intervertebral axial rotation for all vertebrae in the second hemicurvature (not shown) is further computed. The mean of the first and second sums Σθ AXIAL1 , Σθ AXIAL2 is then computed to obtain the value of the torsion. As discussed above, geometrical torsion may also apply.
In a specific embodiment, the output of the prediction method was defined as the main Cobb angle measured on a posteroanterior (PA) radiograph at the earliest visit where skeletal maturity (minimum Risser 4) was reached or just before fusion surgery.
FIG. 5 is a flowchart of an exemplary method for generating the predictive model 500 . The first step 502 was to assess the normality of the output data from a frequency histogram as well as from subjective analysis of the normal distribution.
Due to the large number of variables, the second step 504 was to do univariate analyses to select the most relevant predictors to be included in the multivariate analysis. Initially, the correlations between final Cobb angle at skeletal maturity and local, regional and global parameters of the spine can be performed in order to identify parameters associated with a p value of 0.1 or less.
The third step 506 was done to reduce the number of categories for the curve type. A one-way analysis of variance (ANOVA) can be done to compare the six different curve types in terms of final Cobb angle at skeletal maturity with a level of significance of 0.05, in order to merge curve types resulting in similar final Cobb angle at skeletal maturity. The objective of this step was to reduce the number of different categories for the type of curve input in the model.
The final step 508 consisted in creating the predictive model based on a General Linear Model (GLM). A backward selection procedure approach was performed to select predictors. P-values were first obtained for each predictor included in the full model (curve type and skeletal maturity stage were included as fixed factors and all retained spinal parameters were included as covariates). Interaction was added between categorical variable to test if a change in the simple main effect of one variable over the level of the second was significant.
The predictor with the larger p-value was then eliminated and the model was refitted. This was done until all remaining predictors were associated with a p-value smaller than the stopping criterion set at 0.05. In the GLM, association between the final Cobb angle at skeletal maturity and selected predictors was assessed and expressed as beta coefficient (β coefficient) and 95% confidence interval (CI).
All statistical analyses were done with SPSS 20.0 software package (SPSS, inc., Chicago, Ill., USA).
In one exemplary embodiment, a prospective cohort of 133 AIS was followed from skeletal immaturity to maturity (mean 37 months). A total of 172 AIS patients were entered in the cohort. At the time of the analysis, 133 patients could be included (77.3%). Overall, 17 were lost to follow up, 13 were still skeletally immature and 3D reconstruction was impossible for 9 patients due to calibration errors. Descriptive characteristics of the cohort are presented in table 1, using the following acronyms: n (sample size), TR (triradiate cartilage), RT (right thoracic), RT-LL (right thoracic-left lumbar), LL-RT (left lumbar-right thoracic), LTL (left thoracolumbar), other (left thoracic, right lumbar).
TABLE 1
Cohort
N
133
Age (years)
12.6 ± 1.2
Sex
Male
16
Female
117
Risser
0 and TR open
48
0 and TR closed
47
1
38
Cobb angle (degrees)
22.1 ± 8.4
Follow up (month)
36.7 ± 13.6
Type
RT
35
RT-LL
22
LL-RT
26
Triple
7
LTL
36
Other
7
Treatment
Observation
51
Brace
66
Fusion surgery
16
Computerized measurements were done on reconstructed 3D spines radiographs of the first visit. There were six (6) categories of measurements or parameters, each category comprising several measurements or parameters: angle of plane of maximum curvature, Cobb angles (kyphosis, lordosis), 3D wedging (apical vertebra, apical disks), rotation (upper and lower junctional vertebra, apical vertebra, thoracolumbar junction), mean peri-apical intervertebral rotation (geometrical and/or mechanical torsion) and slenderness (height/width ratio). A general linear model analysis with backward procedure was done with final Cobb angle (either just before surgery or at skeletal maturity) as outcome and 3D spine parameters as predictors. Skeletal maturity stage and type of curvature were also included in the model.
In a specific embodiment, the predictive model was obtained with a determination coefficient of 0.715. Included predictors were a three (3) stages skeletal maturity system and type of curvature. The initial frontal Cobb angle was also included as well as the angle of the plane of maximal curvature. The four (4) other predictive factors of final Cobb angle were the 3D wedging of T3-T4, T8-T9 and T11-T12 disks, and the sum of 3D wedging of all thoracic and lumbar disks. As discussed above, it should be understood that, in other embodiments, 3D wedging of junctional and peri-apical disk levels other than T3-T4, T8-T9, and T11-T12 may apply.
The final Cobb angle distribution followed a normal distribution, as shown by the histogram presented in FIG. 6 .
Pearson's correlations with the final Cobb angle were done for a total of forty-one (41) spinal parameters. There were thirty (30) parameters resulting in a correlation associated with a p-value under 0.1. The results of the correlation analysis are illustrated in table 2.
TABLE 2
Parameters
Pearson coefficient
P-value
3D kyphosis (T4-T12)
−0.285
0.001
Mean apical disks 3D wedging
0.364
0.000
Proximal disk 3D wedging
0.23
0.007
Distal disk 3D wedging
−0.174
0.043
Distal IV rotation
−0.16
0.063
Thoracolumbar IV rotation (T12-L1)
−0.159
0.071
Apical IV rotation
−0.164
0.057
Cobb angle in the plane of maximal
0.287
0.001
deformation
Angle of the plane of maximal
0.501
0.000
deformation
Torsion
0.412
0.000
Cobb angle frontal plane
0.659
0.000
T6 Slenderness (depth)
−0.169
0.050
T6 Slenderness (width)
−0.183
0.034
L4 Slenderness (depth)
−0.203
0.018
L4 Slenderness (width)
−0.165
0.055
T1-L5 Slenderness (width)
−0.226
0.008
T1-L5 Slenderness (depth)
−0.198
0.021
T1-T2 3D disk wedging
0.379
0.000
T2-T3 3D disk wedging
0.268
0.002
T3-T4 3D disk wedging
0.386
0.000
T5-T6 3D disk wedging
0.182
0.034
T6-T7 3D disk wedging
0.192
0.025
T7-T8 3D disk wedging
0.33
0.000
T8-T9 3D disk wedging
0.466
0.000
T9-T10 3D disk wedging
0.314
0.000
T10-T11 3D disk wedging
0.341
0.000
T11-T12 3D disk wedging
0.249
0.004
T12-L1 3D disk wedging
0.305
0.000
L1-L2 3D disk wedging
0.184
0.033
Sum of 3D disks wedging
0.412
0.000
(Thoracic and lumbar)
For the type of curvature, the ANOVA analysis reduced the six (6) categories into four (4) types which are (1) right thoracic, double with main left lumbar and other type (left thoracic, right lumbar), (2) triple, (3) left thoracolumbar, and (4) double with main right thoracic.
With regards to the GLM analysis, skeletal maturity, type of curve, 2D initial Cobb angle, angle of the plane of maximal deformation, disk wedging of T3-T4, T8-T9, T11-T12 and sum of lumbar and thoracic wedging were found to be predictors of the final Cobb angle. Table 3 illustrates the GLM (R 2 =0.715, F=22.956, p<0.000) to determine predictors of final Cobb angle.
TABLE 3
Esti-
mated
coef-
95% CI
p-
Parameters
n
ficient
Upper
Lower
value
Intercept
133
0.288
−7.788
8.364
0.944
Angle of plane of
133
0.177
0.097
0.256
0.000
maximal curvature
2D Cobb angle
133
0.714
0.479
0.949
0.000
T3-T4 disk wedging
133
1.185
0.456
1.914
0.002
T8-T9 disk wedging
133
0.992
0.24
1.745
0.010
T11-T12 disk wedging
133
0.868
0.133
1.603
0.021
Sum of all thoracic and
133
−0.134
−0.251
−0.016
0.026
lumbar disk wedging
Matu-
0
48
8.7
1.041
16.359
0.026
rity
1
85
0 b
Type of
1
68
−4.566
−9.599
0.466
0.075
curvature
2
7
3.959
−8.637
16.556
0.535
3
36
−3.201
−8.728
2.326
0.254
4
22
0 b
Matu-
Interaction
Type
rity
1
0
26
−2.868
−11.454
5.718
0.510
1
1
42
0 b
2
0
5
8.969
−6.854
24.793
0.264
2
1
2
0 b
3
0
10
−14.56
−24.276
−4.843
0.004
3
1
26
0 b
4
0
7
0 b
4
1
15
0 b
All continuous predictors increased the final value of Cobb angle except the sum of disk wedging for which the β coefficient is negative (−0.134). The initial Cobb angle has a coefficient of 0.714. If the patient has a skeletal maturity stage of 0, 8.7° are added to the final Cobb angle prediction when compared to a similar patient with skeletal maturity stage 1. For the type of curvature, 4.6° (type 1) or 3.2° (type 3) are subtracted to the final Cobb angle, or 4.0° is added for type 2, when compared to a similar patient with a type 4 curve. This is adjusted with the interaction contribution. A type 1 with 0 as maturity stage will have 2.9° subtracted, a type 2 with 0 as maturity stage will have 9.0° added and type 3 with 0 as maturity stage will have 14.6° subtracted to the final Cobb angle prediction. R2 of this predictive model is 0.715, which means that it explains 71.5% of variance.
Some p-values for the categorical predictors are over 0.05 when evaluating their main effect in the GLM. However, these categorical predictors were kept in the model because their contribution was significant when considered in interaction between each other.
Predictors of progression were identified for immature patients with AIS that will facilitate the prediction of progression until skeletal maturity in mild and moderate curves with a Cobb angle between 11° and 40°. The prediction model can explain 71.5% of the variance in the final Cobb angle at skeletal maturity using only information taken from the initial visit.
Basics predictors included in the model are the Cobb angle, type of curvature and skeletal maturity at the initial visit.
One 3D parameter comprised in the model is the angle of the plane of maximal deformation. This parameter is associated with the rotation of the curve and may be more sensitive to detect progressive AIS than traditional Cobb angle.
The four (4) other predictors comprised in the model are disc wedging (at junctional and peri-apical disk levels, e.g. T3-T4, T8-T9, T11-T12, and sum of all). T3-T4 and T11-T12 levels that were identified usually represent junctional level and T8-T9 either junctional or apical level depending on the type of curvature (for a thoracic curve it will represent apical level and for thoracolumbar curve, junctional level). Wedging of T3-T4 disks has the largest effect on final Cobb angle prediction.
The statistical model chosen was a GLM with a backward procedure to select the predictors. A stepwise selection variant is widely used in medical application and it was chosen because it represents a good strategy to find the best fitting model. It is accepted that a sample size of more than a hundred (100) is required for linear modeling. Another way to determine the sample size of linear modeling is to have at least ten (10) times the degree of freedom included in model. This model has thirteen (13) degrees of freedom (six (6) continuous predictors, one (1) for maturity stage, three (3) for curve type and three (3) for the combination of maturity stage and type of curvature), so the sample size of one hundred and thirty three (133) is suitable.
Referring to FIG. 7 , a communication system 700 for providing health care providers with support in predicting a curve of progression for AIS will now be described. The system 700 comprises a plurality of devices as in 702 adapted to communicate with a predictive model system 704 over a network 706 . The devices 702 comprise any device, such as a personal computer, a personal digital assistant, a smart phone, or the like, which is configured to communicate over the network 706 , such as the Internet, the Public Switch Telephone Network (PSTN), a cellular network, or others known to those skilled in the art. Although illustrated as being separate and remote from the devices 702 , it should be understood that the predictive model system 704 may also be integrated with the devices 702 , either as a downloaded software application, a firmware application, or a combination thereof.
One or more databases 708 may be integrated directly into the predictive model system 704 or may be provided separately and/or remotely therefrom, as illustrated. In the case of a remote access to the databases 708 , access may occur via any type of network 706 , as indicated above. The databases 708 may be provided as collections of data or information organized for rapid search and retrieval by a computer. The databases 708 may be structured to facilitate storage, retrieval, modification, and deletion of data in conjunction with various data-processing operations. The databases 708 may consist of a file or sets of files that can be broken down into records, each of which consists of one or more fields. Database information may be retrieved through queries using keywords and sorting commands, in order to rapidly search, rearrange, group, and select the field. The databases 708 may be any organization of data on a data storage medium, such as one or more servers.
In one embodiment, the databases 708 are secure web servers and Hypertext Transport Protocol Secure (HTTPS) capable of supporting Transport Layer Security (TLS), which is a protocol used for access to the data. Communications to and from the secure web servers may be secured using Secure Sockets Layer (SSL). Identity verification of a user may be performed using usernames and passwords for all users. Various levels of access rights may be provided to multiple levels of users.
Alternatively, any known communication protocols that enable devices within a computer network to exchange information may be used. Examples of protocols are as follows: IP (Internet Protocol), UDP (User Datagram Protocol), TCP (Transmission Control Protocol), DHCP (Dynamic Host Configuration Protocol), HTTP (Hypertext Transfer Protocol), FTP (File Transfer Protocol), Telnet (Telnet Remote Protocol), SSH (Secure Shell Remote Protocol).
Referring now to FIG. 8 , the predictive model system 704 illustratively comprises a user interface 802 through which the user may interact with the predictive model system 704 . In particular and as will be discussed in further detail herein below, the user (e.g. a physician) may use the user interface 802 to submit information to the predictive model system 704 . As indicated above, the information may be obtained during the first visit, and comprise basis predictors, such as Cobb angle, type of curvature, and skeletal maturity, as well s 3D morphologic parameters. The user interface 802 may be used to access the information from a memory 806 located locally or remotely from the predictive model system 704 .
The predictive model system 704 further comprises a processor 804 , which may be any device that can perform operations on data. Examples are a central processing unit (CPU), a front-end processor, a microprocessor, a graphics processing unit (GPUNPU), a physics processing unit (PPU), a digital signal processor, and a network processor. A plurality of applications 808 a . . . 808 n are illustratively running on the processor 804 for performing operations required at the processor 804 in order to output a predicted final Cobb angle based on the information entered via the user interface 802 . It should be understood that while the applications 808 a . . . 808 n presented herein are illustrated and described as separate entities, they may be combined or separated in a variety of ways.
The processor 804 is in communication with memory 806 which may receive and store data. The memory 806 may be a main memory, such as a high speed Random Access Memory (RAM), or an auxiliary storage unit, such as a hard disk or flash memory. The memory 806 may be any other type of memory, such as a Read-Only Memory (ROM), Erasable Programmable Read-Only Memory (EPROM), or optical storage media such as a videodisc and a compact disc.
FIG. 9 illustratively represents application 808 a for generating a final Cobb angle prediction. Two-dimensional images of the spine, such as those obtained from radiographic imaging systems or other imaging systems, are provided to a spine reconstruction module 902 . Three-dimensional morphology of the spine is thus provided and a 3D parameters extraction module 904 is configured to receive the 3D data and extract therefrom parameters such as the initial Cobb angle, the plane of maximal deformation, the three-dimensional wedging of vertebral body and disk, the axial intervertebral rotation of the apex, upper and lower junctional level and thoracolumbar level, slenderness, and torsion. These parameters are provided to a modeling unit 906 and combined with the skeletal maturity and curve type parameters to model the progression curve of AIS and output a final Cobb angle prediction value. The output of the predictive model system 704 is an aid to the treating physician to determine if the risk of progression warrants additional treatment.
In some embodiments, the predictive model system 704 is further adapted to sketch the curve of progression using the initial Cobb angle and the final Cobb angle. This curve may be output to the user via the user interface 802 or another output device, such as a printer. In some embodiments, the predictive model system 704 is also adapted to select from a series of recommended treatment options as a function of the final Cobb angle and/or the curve of progression generated using the initial and final Cobb angles. The treatment options may be categorized as a function of ranges of final Cobb angles and/or rates of change of the curve of progression such that selection is made of a most appropriate recommended treatment. The selected treatment(s) may then be output to the devices 702 for rendering thereon via the user interface 802 or other output device. Other embodiments for assisting the treating physician with treatment options once the final Cobb angle prediction has been generated will be readily understood by those skilled in the art.
While illustrated in the block diagrams as groups of discrete components communicating with each other via distinct data signal connections, it will be understood by those skilled in the art that the present embodiments are provided by a combination of hardware and software components, with some components being implemented by a given function or operation of a hardware or software system, and many of the data paths illustrated being implemented by data communication within a computer application or operating system. The structure illustrated is thus provided for efficiency of teaching the present embodiment. It should be noted that the present invention can be carried out as a method, can be embodied in a system, or on a computer readable medium. The embodiments of the invention described above are intended to be exemplary only. The scope of the invention is therefore intended to be limited solely by the scope of the appended claims. | There is described a system, method, and computer-readable medium having stored thereon executable program code for generating a final Cobb angle prediction for idiopathic scoliosis, the method comprising: receiving patient-specific 3D morphological spine parameters, a selected curve type, and a selected skeletal maturity; applying the patient-specific 3D morphological spine parameters, a selected curve type, and a selected skeletal maturity to a predictive model based on 3D morphological spine parameters, curve type, and skeletal maturity, and generating the final Cobb angle prediction by modeling a progression curve of the idiopathic scoliosis. | 59,102 |
This application claims priority to prior Japanese patent application JP 2004-171271, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to a card connector for use in connecting a card and, in particular, to a card connector capable of preventing a card from jumping out when the card is ejected.
Japanese Unexamined Patent Application Publication (JP-A) No. 2001-267013 discloses a card connector of a push-push type. The card connector comprises an insulator, a plurality of contacts fixed to the insulator, an eject bar mounted to a frame portion of the insulator, a compression coil spring continuously urging the eject bar in an ejecting direction, and a cam follower guided by a heart cam formed on the eject bar.
A card is inserted into the connector and ejected from the connector. When the compression coil spring pushes the eject bar upon ejecting the card, the card may undesirably jump out. In this event, the card is dropped and, in the worst case, damaged.
Japanese Unexamined Patent Application Publication (JP-A) No. H6-162281 discloses a connecting structure of an IC card to an external equipment. When the IC card is inserted into the external equipment, the IC card is placed on a sliding plate. The sliding plate is urged by a spring in an ejecting direction. In order to eject the IC card from the external equipment, a push button is pushed. Then, the IC card is released from a connector. The IC card and the sliding plates are ejected from the external equipment under an urging force of the spring.
The external equipment adapted to receive the IC card which is inserted therein and ejected therefrom is provided with a braking portion formed adjacent to a card slot at a position under the card slot. The braking portion is formed by a flat rubber plate of synthetic rubber or natural rubber and is fixedly attached by an adhesive. When the sliding plate is ejected from the external equipment, the sliding plate is contacted with the braking portion so that frictional resistance is produced. Therefore, the sliding plate is slowly ejected from the external equipment and the IC card is prevented from jumping out from the external equipment. With the above-mentioned structure, however, the frictional resistance between the sliding plate and the braking portion is unstable and weak.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a card connector which is capable of reliably preventing a card from jumping out when the card is ejected.
It is another object of the present invention to provide a card connector of the type described, which has a retarding mechanism for retarding an ejecting operation of the card.
Other objects of the present invention will become clear as the description proceeds.
According to an aspect of the present invention, there is provided a card connector for use in connecting a card, the card connector comprising a housing for receiving the card, an eject mechanism coupled to the housing for executing an ejecting operation of ejecting the card from the housing, and a retarding mechanism cooperating with the eject mechanism to retard the ejecting operation.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a front view of a card connector according to a first embodiment of this invention when a card is inserted therein;
FIG. 2 is a front view of the card connector in FIG. 1 during ejection of the card;
FIG. 3 is front view of the card connector in FIG. 1 after the card is ejected therefrom;
FIG. 4 is a view for describing a shape of a heart cam included in the card connector in FIG. 1 ;
FIG. 5 is a view for describing an operation of the heart cam of FIG. 4 ;
FIG. 6 is a front view of a card connector according to a second embodiment of this invention when a card is inserted therein although not shown in the figure;
FIG. 7 is a sectional view taken along a line VII—VII in FIG. 6 ;
FIG. 8A is a sectional view of a modification of the card connector of FIG. 6 when the card is inserted therein; and
FIG. 8B is a sectional view similar to FIG. 8A when the card is ejected therefrom.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 to 3 , a card connector according to a first embodiment of the present invention will be described.
The card connector depicted at 1 in FIGS. 1 through 3 comprises an insulating housing 2 made of synthetic resin, a plurality of conductive contacts 3 fixed to the housing 2 , an eject bar 4 made of synthetic resin and attached to a frame portion of the housing 2 , a compression coil spring 5 continuously urging the eject bar 4 in an ejecting direction A 1 , and a cam follower 6 having a first end 6 a which is guided by a heart cam 7 formed on the eject bar 4 . A combination of the eject bar 4 , the compression coil spring 5 , the cam follower 6 , and a heart cam 7 is referred to as an eject mechanism 10 .
The contacts 3 are arranged in a single row and held inside the housing 2 of the card connector 1 in an area near the center of an inner portion 2 a of the housing 2 . The eject bar 4 is held inside the housing 2 on a left side thereof to be slidable in a vertical direction in the figures. More particularly, the eject bar 4 is contained in the housing 2 to be movable in the ejecting direction A 1 and an inserting direction A 2 opposite to the ejecting direction A 1 . The compression coil spring 5 continuously urges the eject bar 4 towards an inlet portion 2 b of the housing 2 , i.e., in the ejecting direction A 1 . Specifically, the compression coil spring 5 has one end and the other end kept in press contact with the eject bar 4 and an inner surface of the frame portion of the housing 2 , respectively.
The cam follower 6 is made of a metal material and has a second end 6 b which is engaged with an axial hole formed on the frame portion of the housing 2 and which is rotatable by a predetermined angle. The first end 6 a of the cam follower 6 is engaged with a groove of the heart cam 7 .
A card 11 is inserted into the connector 1 in the inserting direction A 2 and ejected from the connector 1 in the ejecting direction A 1 . The eject bar 4 has a protruding portion 4 b. When the card 11 is inserted into the connector 1 , one corner of a forward end of the card 11 is brought into contact with the protruding portion 4 b. Further, the housing 2 is provided with a rubber brake 8 fixed thereto on a left side of the inlet portion 2 b. The rubber brake 8 is made of an elastically deformable rubber material known in the art.
Referring to FIGS. 4 and 5 , the heart cam 7 will briefly be described. The heart cam 7 is formed on a protruding portion 4 c of the eject bar 4 . The heart cam 7 is formed as an annular guide rail or a cam groove having a first point P 1 , a second point P 2 , a third point P 3 , a fourth point P 4 , and a fifth point P 5 . The first point P 1 is a start point of movement of the first end 6 a of the cam follower 6 . The second point P 2 is located in a guide portion slightly inclined with respect to the ejecting and the inserting directions A 1 and A 2 . The third point P 3 is located in a heart-like recessed portion. The fourth point P 4 is located in a guide portion substantially parallel to the ejecting and the inserting directions A 1 and A 2 . The fifth point P 5 is an end point of the movement of the first end 6 a of the cam follower 6 . The fifth point P 5 is identical with the first point P 1 . In a free state of the connector 1 , the first end 6 a of the cam follower 6 is urged rightward in FIG. 4 by elasticity of the cam follower 6 .
Following sliding movement of the eject bar 4 , the first end 6 a of the cam follower 6 moves along the heart cam 7 in the order of the first point P 1 , the second point P 2 , the third point P 3 , the fourth point P 4 , and the fifth point P 5 . Depending upon a position of the first end 6 a of the cam follower 6 , the connector 1 is changed from the free state into a mating state and vice versa, as illustrated in FIG. 5 .
Turning back to FIGS. 1 to 3 , description will be made of insertion and ejection of the connector 1 into and from the card 11 .
When the card 11 is inserted into the housing 2 by operator's fingers, the one corner of the forward end of the card 11 pushes the protruding portion 4 b of the eject bar 4 . Consequently, the eject bar 4 presses the coil spring 5 and slides in the inserting direction A 2 from the inlet portion 2 b towards the inner portion 2 a. Upon completion of insertion of the card 11 , a plurality of contact points (not shown) of the card 11 are connected to the contacts 3 of the card connector 1 . At this time, an operation or movement of the eject bar 4 is restricted by the cam follower 6 .
In order to eject the card 11 from the housing 2 , a push button (not shown) formed on the housing 2 or the card 11 itself is pushed. Then, the eject bar 4 is unlocked from the cam follower 6 and slides in the ejecting direction A 1 from the inner portion 2 a towards the inlet portion 2 b under restoring force of the coil spring 5 to reach a state illustrated in FIG. 2 . At this time, the protruding portion 4 b of the eject bar 4 pushes the forward end of the card 11 . Consequently, the card 11 reaches the state illustrated in FIG. 2 together with the eject bar 4 . In this state, one end 4 a of the eject bar 4 starts to compress the rubber brake 8 in a compressing direction, namely, the ejecting and the inserting directions A 1 and A 2 . Subsequently, as illustrated in FIG. 3 , the rubber brake 8 is elastically deformed in a direction perpendicular to the compressing direction so that a butting portion 8 a at an end of a triangular part of the rubber brake 8 is brought into press contact with one side of the card 11 . As a result, the card 11 is braked by friction between the card 11 and the rubber brake 8 . In other words, the rubber brake 8 makes the card 11 be slowed in an ejecting operation thereof. Therefore, the card 11 is prevented from undesirably jumping out from the housing 2 . At this time, the rubber brake 8 serves as a braking mechanism for braking the card 11 or a retarding mechanism for retarding ejection of the card 11 .
Preferably, the rubber brake 8 is provided with a hollow portion 8 b. In this event, the rubber brake 8 is easily elastically deformed. At this time, the hollow portion 8 b serves as an auxiliary mechanism for effectively causing elastic deformation of the rubber brake 8 .
Referring to FIGS. 6 and 7 , description will be made of a card connector according to a second embodiment of this invention. Similar parts are designated by like reference numerals and description thereof will be omitted.
The card connector 1 uses an air spring instead of the rubber brake 8 in the card connector illustrated in FIGS. 1 through 3 . The air spring has a cylindrical portion 27 formed in the housing 2 . The cylindrical portion 27 is provided with an air-relief hole 28 . The air-relief hole 28 allows an inner space of the cylindrical portion 27 to communicate through a rear surface of the housing 2 with an outside. A part of the eject bar 4 is inserted into the cylindrical portion 27 .
The air-relief hole 28 has a sectional area extremely narrower than that of the cylindrical portion 27 . With this structure, when the card is ejected from the card connector 1 , air does not easily flow out from the cylindrical portion 27 through the air-relief hole 28 to the outside. Consequently, the eject bar 4 slides slowly. This means that a combination of the cylindrical portion 27 and the air-relief hole 28 serves to make the eject bar 4 be slowed in movement thereof in the ejecting direction A 1 . Accordingly, the card is prevented from undesirably jumping out from the housing 2 . At this time, a combination of the cylindrical portion 27 and the air-relief hole 28 serves as a braking mechanism for braking the eject bar 4 or a retarding mechanism for retarding ejection of the card.
As shown in FIGS. 8A and 8B , an air valve 29 may be provided to open and close the air-relief hole 28 . In this case, the air valve 29 is made of an elastically deformable material.
When the card is inserted, the eject bar 4 is pushed by the card and moved in the inserting direction A 2 of FIG. 8A . In this event, the air valve 29 opens the air-relief hole 28 as depicted by a lower white arrow 31 in FIG. 8A so that air flows through the air-relief hole 28 into the cylindrical portion 27 .
When operation is carried out to eject the card in the manner known in the art, the eject bar 4 slides in the ejecting direction A 1 of FIG. 8B . In this event, air moves in the cylindrical portion 27 towards the air-relief hole 28 to make the air valve 29 be faced to the air-relief hole 28 as depicted by a lower white allow 32 in FIG. 8B . As a consequence, the air is compressed in the cylindrical portion 27 in the ejecting and the inserting directions A 1 and A 2 .
Although the air valve 29 faces the air-relief hole 28 , the air is allowed to flow by little and little through the air-relief hole 28 . For example, a small gap is formed between the air valve 29 and the air-relief hole 28 or the air valve 29 is provided with a small hole or holes. Therefore, the eject bar 4 slides slowly and the card is prevented from undesirably jumping out from the housing 2 .
While the present invention has thus far been described in connection with the preferred embodiments thereof, it will readily be possible for those skilled in the art to put this invention into practice in various other manners. For example, a plurality of contacts are provided in each of the foregoing embodiments. However, this invention is also applicable to the case where only one contact is provided. | In a card connector for use in connecting a card, an eject mechanism is coupled to a housing for receiving the card. The eject mechanism is for executing an ejecting operation of ejecting the card from the housing. The card connector is provided with a retarding mechanism which cooperates with the eject mechanism to retard the ejecting operation. The retarding mechanism may include a braking mechanism for braking the card in response to an operation of the eject mechanism. Alternatively, the braking mechanism may be for braking an eject bar which is included in the eject mechanism and movable along the housing for ejecting the card. | 14,432 |
FIELD OF THE INVENTION AND RELATED ART
The present invention relates to an ink jet recording head, and an ink jet recording apparatus employing an ink jet recording head.
A recording apparatus which uses an ink jet recording head is advantageous in that it is low in noise and operational cost. Further, the employment of an ink jet recording head makes it easier to reduce a recording apparatus in size, and also, to enable a recording apparatus to record in color. An image recorded with the use of an ink jet recording apparatus is made up of dots created by droplets of ink. Thus, in order to form a black-and-white image which is less grainy across its halftone areas, or a photographic color image which is less grainy across its halftone areas and high light areas, various attempts have been made to reduce an ink jet recording head (apparatus) in ink droplet size. Generally, the ink droplets jetted from recording heads for jetting color inks are 5 pl, 2 pl, etc., in volume (size), which are substantially smaller than the volume (roughly 15 pl) by which ink is jetted from an ordinary recording head for black-and-white printing. Further, in the recent years, not only have significant advancements been made in the field of digital input devices, but also, digital input devices have come to be widely used. Consequently, demands have been continuously increasing for ink jet recording apparatuses capable of printing a highly precise image, such as a photographic image, at a very high level of accuracy. Thus, it has become necessary to produce an ink jet recording head capable of jetting ink droplets which are as small as 1 pl in volume. Thus, it has become necessary to reduce an ink jet recording head in the size of the ink jetting opening of each of its nozzles.
The smaller the size of the ink jetting opening of each of its nozzles of an ink jet recording head, the greater the amount by which water evaporates from the body of ink in the nozzle, which is in the adjacencies of the opening, while ink is not jetted from the nozzle. Thus, the smaller the size of the ink jetting opening of each of its nozzles of the ink jet recording apparatus, the more likely the body of ink in each nozzle of the ink jet recording head to increase in viscosity, and therefore, the more likely the ink jet recording head to suffer from the problem that it fails to properly jet ink, because of the plugging of the nozzles by the body of the ink having increased in viscosity (ink droplets are jetted in an abnormal direction, and/or fail to reach recording paper). One of the conventional solutions to this problem is as follows. That is, an ink jet recording head was made to jet ink immediately before an ink jet recording operation is started, and/or with preset intervals during the recording operation, in such a manner that ink droplets land off the recording sheet. This operation hereafter may be referred to as “maintenance jetting”. More specifically, an ink jet recording apparatus is provided with a waste ink absorbing member, which is located in the recording apparatus, or an opening dedicated to the reception of the ink jetted for maintenance. This operation is carried out as necessary, or with preset intervals. In the maintenance operation, several ink droplets —10 plus ink droplets— are jetted with an interval of roughly 2-15 seconds, although the number of ink droplets and the interval are adjusted according to the ink jetting force of an ink jet recording head in use, how quickly the inks in use lose their liquid content(s), and ambient temperature. In this maintenance operation, that is, the conventional maintenance operation, however, a recording head has to be moved to a preset location, for example, where the waste ink absorbing member is located. In other words, if this maintenance operation is carried out during a printing operation, that is, while images are formed on one or more sheets of recording paper, the recording head has to be moved out of the recording range of a sheet of recording paper, and therefore, the actual length of time available for printing images based on a unit of recording data (which hereafter will be referred to as throughput) becomes significantly shorter. This problem becomes exacerbated when an ink jet recording apparatus is operated in a high speed mode, in which the recording head is moved at the highest speed and highest capacity to minimize the length of time necessary per sheet of recording paper. In some cases, the ratio of the “maintenance jetting” amounts to a value as large as several percent to 10 plus percent.
To describe more concretely, it is assumed that an image is formed on a sheet of recording paper of A4 size (8″×11″), which is 20.32 cm×27.94 cm in printable area, and also, that each area of the image, which is equivalent to a single raster, is formed by a single scan of the recording sheet by the recording head in the widthwise direction of the recording sheet. In order to complete an intended image on the recording sheet of the abovementioned size, with the use a recording head, which is 5.33 mm (0.21 inch) in size and 5 pl in ink droplet size, and each column of nozzles of which has 256 nozzles aligned at a density of 1,200 dpi, the recording head has to scan the recording sheet roughly 52 times (number of times recording head has to scan recording sheet; number of times recording sheet has to be moved in its lengthwise direction). If the frequency at which the recording head is driven is 15 kHz, the moving (scanning speed) of the recording head is 63.5 cm (25 inches)/sec. Thus, assuming that the sum of the length of time necessary for moving the recording sheet in its lengthwise direction, and length of time necessary for the recording head to ramp up or down, is roughly 0.1 second, it takes roughly 0.52 second to complete an area of image, which is equivalent to a raster. Thus, the length of time necessary to complete an image on a single sheet of recording paper, which is A4 in size, is roughly 27 seconds. To roughly calculate the ratio of the maintenance jetting per page, if the interval for the maintenance jetting is 5 seconds, the number of times inks are jetted for maintenance per page is 5, which amounts to roughly 10% (=5 scans/52 scans) of the overall recording time. On the other hand, in the case of a recording head, which is smaller in ink droplet size, for example, 2 pl, the interval for the maintenance jetting has to be reduced to roughly 2 seconds. Thus, the ratio of the maintenance jetting, which is calculated in this case, using the same method as that described above, is roughly 25% (=13 scans/52 scans) of the overall recording time. In other words, the smaller the ink droplet size, the higher the rate of the maintenance jetting, and therefore, the lower the throughput.
As for the means for minimizing the problem that an ink jet head is reduced in throughput by the operation for maintaining the ink jet head, a means for reducing the need for carrying out an ink jetting operation dedicated to the maintenance of a recording head, is disclosed in Japanese Laid-open Patent Application H03-112904. According to this patent application, ink droplets, which are not intended for image formation, are jetted onto a sheet of recording paper while forming an image. More specifically, the ink droplets, which are not intended for image formation, are jetted onto the recording sheet so that they land on the areas of the sheet, which correspond to the edge portions of the image being formed, or, are jetted onto the recording sheet in a manner of effecting pseudo watermarks on the recording sheet.
All that is necessary to prevent the problem that a recording head is reduced in throughput by the operation for maintaining the recording head is to reduce the length of time necessary for the maintenance operation. One of the desired means for reducing the length of time necessary for the maintenance operation is to jet the ink droplets, which are intended for the maintenance, onto the recording sheet while forming an image, instead of moving the recording head to a preset location, away from the recording sheet, to carry out the maintenance operation.
The means disclosed in the abovementioned Japanese Laid-open Patent Application H08-112904is desirable in that the ink droplets for maintenance are jetted onto the recording sheet in such a pattern that the ink droplets land on the areas of the recording sheet, which correspond to the edge portions of the image being formed, or jetted in a manner of effecting pseudo watermarks on the recording sheet. This means, however, is not desirable in that the dots formed by the ink droplets jetted for maintenance are recognizable. Thus, this means is not desirable when forming a high quality image. Hence, it is desired to enable an ink jet recording head, in particular, an ink jet recording head for printing a highly precise image, such as a photographic image, to jet the ink droplets for maintenance, that is, the ink droplets which are not intended for image formation, onto a sheet of recording paper, without having ill effects on the image being formed. In order for the ink droplets jetted for maintenance to have no ill effects upon the image being formed, the dots formed by the ink droplets jetted for maintenance have to be as inconspicuous as possible. Thus, the object of the present invention is to ensure that the dots which will be formed on a sheet of recording paper by the ink droplets intended for maintenance will be as low as possible in visibility.
Obviously, the smaller the volume by which ink is jetted in the form of a droplet, the lower in visibility the dot formed by the ink droplet. Generally, however, the reduction in the ink droplet size of an ink jet recording head results in the reduction in the throughput of the ink jet recording head, unless the ink jet head is increased in the number of the ink droplets it can jet per unit length of time. One of the means for increasing the number of the ink droplets an ink jet recording head can jet is to increase the ink jet recording head in nozzle count. In order to increase an ink jet recording head in nozzle count, it is necessary to increase the ink jet recording head in size (chip size), which results in the increase in the cost of the ink jet recording head. That is, the relationship between the throughput of an ink jet recording head and the cost of the ink jet recording is a tradeoff. Therefore, it is important that the optimal ink droplet size for an ink jet recording head be determined in consideration of this relationship.
SUMMARY OF THE INVENTION
The primary object of the present invention is to provide an inexpensive ink jet recording head which is capable of forming high quality images at a significantly higher speed, while keeping at a significantly lower level in visibility, the dots formed on a sheet of recording paper by the ink droplets jetted for the purpose of maintaining the ink jet recording head, than any of the ink jet recording heads in accordance with the prior art.
Another object of the present invention is to provide an ink jet recording apparatus employing the ink jet recording head described above.
According to an aspect of the present invention, there is provided an ink jet recording head comprising a large nozzle array including a plurality of ejection outlets for ejecting ink; a small nozzle array including a plurality of ejection outlets each having an opening area smaller than an opening area of ejection outlets of said large nozzle array, wherein said ink jet recording head is mountable to an ink jet recording apparatus which is capable of causing said ink jet recording head to eject ink for a purpose of maintenance of ink jet recording head without image formation on a recording material, and wherein said large nozzle array is supplied with light ink consisting of yellow, light cyan or light magenta ink, and said small nozzle array is supplied with dark ink consisting of cyan, magenta or black ink, and wherein the number of ejections of the dark ink is larger than the number of ejections of the light ink.
According to another aspect of the present invention, there is provided an ink jet recording apparatus comprising an ink jet recording head according to the present invention of said aspect; and a controller for controlling an ejecting operation for the maintenance and an image forming operation.
According to the present invention, it is possible to provide an inexpensive ink jet recording head which is capable of forming high quality images at a significantly higher speed, while keeping at a significantly lower level in visibility, the dots formed by the ink droplets jetted for the purpose of maintaining the ink jet recording head, than any of the ink jet recording heads in accordance with the prior art, and also, an ink jet recording apparatus employing the ink jet recording head described above.
These and other objects, features, and advantages of the present invention will become more apparent upon consideration of the following description of the preferred embodiments of the present invention, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the recording head cartridge in the first embodiment of the present invention.
FIG. 2 is an exploded perspective view of the recording head portion of the recording head cartridge in the first embodiment of the present invention.
FIG. 3 is a detailed exploded perspective view of the recording head portion in the first embodiment of the present invention.
FIG. 4 is a partially broken perspective view of the first recording chip in the first embodiment of the present invention.
FIG. 5 is a partially broken perspective view of the second recording chip in the first embodiment of the present invention.
FIG. 6 is a sectional view of the recording head cartridge in the first embodiment of the present invention, at a plane perpendicular to the moving direction of the recording head cartridge.
FIG. 7 is a perspective view of the assembled primary structural components of the first embodiment of the present invention.
FIG. 8 is a block diagram of the control circuit of the ink jet recording apparatus in the first embodiment of the present invention.
FIG. 9 is a plan view of the recording chip of the first embodiment of the present invention, as seen from the side where the nozzle openings are located.
FIG. 10 is a detailed view of the surface of the recording chip, at which the nozzle openings are located, in the first embodiment of the present invention, showing in detail the arrangement of the columns of nozzles.
FIG. 11 is a schematic drawing of the matrix for the dot formation on recording medium, in the first embodiment of the present invention.
FIG. 12 is a plan view of the surface of the recording chip of the recording head in the second embodiment of the present invention, as seen from the side where nozzle openings are located.
FIG. 13 is a detailed view of the surface of the recording chip, at which the nozzle openings are located, in the second embodiment of the present invention, showing in detail the arrangement of the columns of nozzles.
FIG. 14 is a plan view of the surface of the recording chip of the third embodiment of the present invention, as seen from the side where nozzle openings are located.
FIG. 15 is a detailed view of the surface of the recording chip, at which the nozzle openings are located, in the third embodiment of the present invention, showing in detail the arrangement of the columns of nozzles.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiment 1
Next, the first preferred embodiment of the present invention will be described with reference to the appended drawings.
First, a typical ink jet head cartridge ( 1 ), with which the present invention is compatible, and a typical ink jet recording apparatus ( 2 ) employing a typical ink jet head cartridge ( 1 ), will be described in detail.
(1) Recording Head Cartridge
FIGS. 1-8 are drawings for describing a preferable recording head cartridge (liquid jetting recording head cartridge), with which the present invention is compatible, the recording head portion thereof, and ink container portion for holding the ink (liquid) for recording, and also, their relationship, will be described. First, each of the above-mentioned structural components will be described with reference to the appended drawings.
Referring to FIG. 1 , in (a) and (b), which are perspective views of the recording head portion H 1001 in accordance with the present invention, the recording head 1001 is one of the essential structural components of the recording head cartridge H 1000 in the first embodiment. The recording head cartridge H 1000 is made up of the recording head portion H 1001 and ink containers H 1900 . The ink container H 1900 is removably connectible to the recording head portion H 1001 . The recording head cartridge H 1000 is mounted on the carriage (unshown) of the main assembly of the ink jet recording apparatus, being precisely positioned relative to the carriage by a recording head cartridge positioning means. It is removably mountable on the carriage. As the recording head cartridge H 1000 is mounted on, or removed from, the carriage, electrical connection is established or broken, respectively, between the recording head cartridge H 1000 and carriage (main assembly).
The recording head cartridge H 1000 (recording apparatus) in this embodiment uses four ink containers H 1900 , namely, an ink container H 1901 for black ink, an ink container H 1902 for cyan ink, an ink container H 1903 for magenta ink, and an ink container H 1904 for yellow ink. These ink containers H 1901 , H 1902 , H 1903 , and H 1904 are removably connectable to the recording head portion H 1001 , independently from each other; they are individually connectable to the recording head portion H 1001 . This structural arrangement makes it possible to replace each ink container H 1900 as necessary, preventing thereby ink from being wasted. Thus, the employment of this structural arrangement makes it possible to reduce an ink jet recording apparatus in printing cost.
Next, the recording head portion H 1001 will be described in more detail, regarding each of its structural components.
(1-1) Recording Head Portion
The recording head of the recording head portion H 1001 in this embodiment is a BUBBLE-JET (registered commercial name) recording head, which uses electrothermal transducers for generating the thermal energy for causing ink to boil in the so-called film-boiling manner, in response to electrical signals. Each electrothermal transducer is positioned opposite an ink jetting opening. That is, the recording head is of the so-called side shooter type.
Referring to FIG. 2 which is an exploded perspective view of the recording head cartridge in the first embodiment of the present invention, the recording head portion H 1001 is made up of a recording element unit H 1002 , an ink supplying unit H 1003 (liquid supplying unit), and an ink container holder H 2000 .
Next, referring to FIG. 3 which is an exploded perspective view of the recording head portion of the first embodiment of the present invention recording head, the recording unit H 1002 is made up of a first recording chip H 1100 , a second recording chip H 1101 , a first plate H 1200 , an electric wiring tape H 1300 (electric wiring chip), an electric contact chip H 2200 , and a second plate H 1400 . Further, an ink supply unit H 1003 is made up of an ink supplying member H 1500 , a flow passage forming member H 1600 , a joint sealing member H 2300 , a filter H 1700 , and a rubber seal H 1800 .
(1-1-1) Recording Unit
The first plate H 1200 is 0.5-10 mm in thickness, and is formed of alumina (Al 2 O 3 ), for example. However, the material for the first plate H 1200 does not need to be limited to alumina. That is, it may be a substance, other than alumina, which is equal or higher in thermal conductivity than the material for the recording chips H 1100 and 1101 . For example, it may be any among silicon (Si), aluminum nitride (AlN), zirconia (ZrO 2 ), silicon nitride (SiN 4 ), silicon carbide (SiC), molybdenum (Mo), and tungsten (W). The first plate H 1200 has four ink supplying holes H 1201 , that is, an ink supplying hole H 1201 for supplying the first recording chip H 1100 with black ink, and three ink supplying holes H 1201 for supplying the second recording chip H 1101 with cyan, magenta, and yellow inks, correspondingly. Further, it has a pair of screw anchoring portions H 1206 , which are located at the edges perpendicular to the lengthwise direction of the ink supplying holes 1201 , to keep the first plate H 1200 reliably fastened to the recording unit H 1002 .
FIG. 4 is a partially broken perspective view of the first recording chip H 1100 in the first embodiment of the present invention, and describes the structure of the recording element chip H 1100 . The first recording chip H 1100 is made up of a substrate H 1110 , two columns of electrothermal transducers H 1103 , and unshown electric wiring. The substrate H 1110 is 0.5- 1mm in thickness, and is formed of silicon. It has an ink supplying hole H 1102 , which is long and narrow at the top and bottom openings. The two columns of electrothermal transducers H 1103 are positioned on each side of the ink supply hole H 1102 , one for one. The electric wiring is for supplying the electrothermal transducers with electric power, and is formed of aluminum or the like. The electrothermal transducers H 1103 and electric wiring are formed by film forming technologies. Further, the electrothermal transducers H 1103 are arranged in a pattern (zig-zag pattern) of foot prints formed on wet sand by a plover. That is, in terms of the direction parallel to the ink supply hole 1102 , the two columns of electrothermal transducers H 1103 are displaced relative to each other so that a given electrothermal transducer in one column does not align with an electrothermal transducer in the other column in terms of the direction perpendicular to the two columns of electrothermal transducers H 1103 . Further, the first recording chip H 1100 is provided with a pair of electrode portions H 1104 for providing the electric wiring with electric power. The two electrode portions H 1104 are placed along the two edges, one for one, of the substrate H 1110 , which are perpendicular to the ink supply holes H 1102 . Each electrode portion H 1104 has a row of bumps H 1105 formed of gold (Au) or the like. The surface of the silicon substrate H 1110 , on which the abovementioned components are located, is covered with a structural components formed of a resinous substance with the use of photolithographic technologies. This structural component has wall portions H 1106 which make up the lateral walls of the ink passages which correspond one for one with the electrothermal transducers H 1103 , and the top wall portion which makes up the top wall of each ink passage. The top wall portion has the opening of each of the ink jetting holes H 1107 (which hereafter may be referred to simply as nozzles). The nozzles H 1107 and electrothermal transducers H 1103 are positioned so that they oppose each other one for one. The nozzles H 1107 are arranged in such a manner that their openings form two columns H 1108 . The ink supplied to each nozzle H 1107 of the first recording chip H 1100 is jetted out of the nozzle H 1107 (which opposes one of the electrothermal transducers), by the pressure generated by a bubble generated by the heat from the corresponding electrothermal transducer.
FIG. 5 is a partially broken perspective view of the second recording chip in the first embodiment of the present invention, which is for describing the structure of the chip. The second recording chip H 1101 is for jetting out three color inks, namely, cyan, magenta, and yellow inks. It has three ink supplying holes H 1102 , which are arranged in parallel. It also has three pairs of columns of electrothermal transducers H 1103 and three pairs of columns of nozzles H 1107 . One of each pair of columns of electrothermal transducers H 1103 is slightly displaced relative to the other, in the direction parallel to the columns, so that as seen from the direction parallel to the columns, the electrothermal transducers H 1103 are arranged in a pattern (zig-zag pattern) of the foot prints left on wet sand by a plover, and so are the ink jetting holes H 1107 . Like the first recording chip H 1100 , the second recording chip H 1101 is made up of a substrate H 1110 formed of silicon, and the electric wiring, electrode portions H 1104 , etc., formed on the substrate H 1110 . Further, the second recording chip H 1101 has ink passage walls H 1106 and ink jetting nozzles H 1107 , which are formed of a resinous substance with the use of photolithographic technologies. The electrode portions H 1104 for supplying the electric wiring with electric power are provided with bumps H 1105 formed of gold (Au) or the like, as are the electrode portions H 1104 of the first recording chip H 1100 .
The recording chips H 1100 and H 1101 are precisely adhered to the first plate H 1200 with the use of a first adhesive, in such a manner that their ink supplying holes 1102 precisely connect with the ink supplying holes of the first plate H 1200 , one for one. The first adhesive is desired to be low in viscosity, low in the temperature at which it hardens, short in the hardening time, relatively hard after its hardening, and resistant to ink. For example, a thermally curable adhesive, the main ingredient of which is epoxy resin, is desirable as the first adhesive. It is also desired that the thickness of the first adhesive layer is no more than 50 μm after its hardening.
The second plate H 1400 is 0.5-10 mm in thickness, and is formed of a ceramic such as alumina (Al 2 O 3 ), or a metallic substance, such as aluminum, stainless steel, etc., for example. It has two holes, which are larger than the first and second recording chips H 1100 and H 1101 fixed to the first plate H 1200 with the use of the adhesive. The second plate 1400 is fixed to the first plate H 1200 with the use of a second adhesive, in such a manner that as the electric wiring tape H 1300 is adhered to the first and second recording chips H 1100 and H 1101 , the electric wiring tape H 1300 remains flat.
The electric wiring tape H 1300 is the electric signal passage, through which the electric signals for causing the first and second recording chips H 1100 and H 1101 to jet ink are applied to the first and second recording chips H 1100 and H 1101 . The electric wiring tape H 1300 has two holes, which correspond in position to the recording chips H 1100 and H 1101 , one for one. It also has two sets of electrical terminals H 1302 , which are to be connected to the electrode portions H 1104 of the recording chips H 1100 and H 1101 , respectively. Further, the electric wiring tape H 1300 has electrical terminal connecting portions H 1303 , which are located at one of its edge portions to make electrical connections between the electric wiring tape H 1300 and an electrical contact chip H 2200 having external signal input terminals H 1301 for receiving electrical signals. The electrical terminals H 1302 and electrical terminal connecting portion H 1303 are in connection with each other through a continuous patterned wiring formed of copper foil. The electric wiring tape H 1300 is fixed to the second plate H 1400 with a third adhesive placed between the back surface of the electric wiring tape H 1300 and the bottom surface of the second plate H 1400 . Further, the electric wiring tape H 1300 is bent in the thickness direction of the first plate H 1200 , and is fixed to one of the lateral surfaces of the first plate H 1200 . As the third adhesive, a thermally curable adhesive, the main ingredient of which is epoxy resin, is used, for example, and is applied by such an amount so that the layer of the third adhesive will be 10-100 μm in thickness after its hardening.
The electrical connection between the electric wiring tape H 1300 and first recording chip H 1100 , and the electrical connection between the electric wiring tape H 1300 and second recording chip H 1101 , are established by connecting the electrode portions H 1104 of the first and second recording chips H 1100 and H 1101 to the electrical terminals H 1302 of the electric wiring tape H 1300 with the use of ultrasonic waves. The electrical joints between the first recording chips H 1100 and electric wiring tape H 1300 , and the electrical joints between the second recording chip H 1101 and electric wiring tape H 1300 , are sealed with a body of a first sealant H 1307 and a body of second sealant H 1308 , respectively, in order to prevent the joints from being corroded by ink, and also, to protect the joints from external impacts. The first sealant H 1307 is primarily used to seal the joints between the electrical terminals H 1302 of the electric wiring tape H 1300 and the electrode portions H 1104 of the recording chips H 1100 and H 1101 , from the back side, and also, to seal the peripheries of the recording chips H 1100 and H 1101 . On the other hand, the second sealant H 1308 is used to seal the joints from the front side. The electric wiring tape H 1300 is in connection with the electrical contact chip H 2200 , which is attached to one of the edge portions of the electric wiring tape H 1300 with the use of a piece of electrically conductive isotropic film or the like, by applying heat and pressure. The electrical contact chip H 2200 has a terminal positioning hole H 1309 and a terminal connection hole H 1310 for its fixation.
(1-1-2) Ink Supply Unit
Referring to FIG. 3 , an ink supplying member H 1500 is one of the structural members of an ink supply unit H 1003 , which is for guiding ink from an ink container H 1900 to the recording unit H 1002 . It is formed of a resin, for example, by molding. It is desired that glass filler is mixed into the resinous material for the ink supplying member H 1500 , by a ratio of 5-40%, in order to make the ink supplying member H 1500 rigid in shape.
Next, referring to FIG. 6 , the ink supplying member H 1500 and an ink container holder H 2000 make up the ink container storage portion in which the ink containers H 1900 are removably mountable. The bottom portion of this ink container storage portion is provided with ink container positioning holes H 1502 , in which the ink container positioning pin H 1908 of each of the ink containers H 1900 fits. The rear wall of the ink container storage portion has: a first hole H 1503 in which the first claw of each ink container H 1900 fits; and a second hole H 1504 in which the second claw H 1910 of each ink container H 1900 fits. On the other hand, the front portion of each of the ink containers H 1900 is provided with an elastic lever H 1912 having a third claw H 1911 , which engages with the wall of the ink container storage portion. This lever H 1912 is elastically deformable by the application of pressure to disengage the third claw H 1911 from the wall of the ink container storage portion so that the ink container H 1900 can be removed. Among the abovementioned structural features, the holes H 1503 and H 1504 are parts of the ink supplying member H 1500 . That is, the ink supplying member H 1500 is a part of the means for removably holding the ink container H 1900 .
The bottom portion of the ink container storage portion of the ink supplying member H 1500 is provided with a connective portion H 1520 , which is placed in contact with the ink outlet hole H 1907 of the ink container H 1900 . The connective portion H 1520 is fitted with a filter H 1700 for preventing the entrance of foreign substances, such as dust in the air. The filter H 1700 is welded to the connective portion H 1520 . Further, the connective portion H 1520 is fitted with the rubber seal H 1800 for preventing the ink evaporation from the joint between the ink supplying member H 1500 and ink container H 1900 . The interior of the ink supplying member H 1500 has an ink passage H 1501 , which extends from its connective portion H 1520 (which is connected to ink container H 1900 ) to its bottom surface. To the bottom surface of the ink supplying member H 1500 , an ink passage forming member H 1600 is attached by ultrasonic welding. The ink passage forming member H 1600 has ink inlet holes H 1602 for supplying the recording unit H 1002 with ink. The ink passage forming member H 1600 is precisely positioned relative to the ink supplying member H 1500 so that the ink inlet holes H 1602 and the ink passages H 1501 of the ink supplying member H 1500 become perfectly connected one for one.
(1-1-3) Joining of Recording Unit and Ink Supply Unit
Next, the joining of the recording unit H 1002 and ink supply unit H 1003 will be described.
The recording unit H 1002 and ink supply unit H 1003 are joined with each other by small screws H 2400 , with the placement of a joint seal 2300 between the two units H 1002 and H 1003 . The joint seal H 2300 is provided with holes, which correspond in position to the ink supplying holes H 1201 of the first plate H 1200 and the ink inlet holes 1602 of the ink passage forming member H 1600 . The joint seal H 2300 is formed of an elastic substance, such as rubber, which is very small in permanent compression deformation. With the interposition of the abovedescribed joint seal H 2300 between the recording unit H 1002 and ink supply unit H 1003 , it is ensured that ink does not leak from the joint between the two units H 1002 and H 1003 . The electrical contact chip H 2200 of the recording unit H 1002 is fixed to the back surface of the ink supplying member H 1500 , being precisely positioned relative to the ink supplying member H 1500 ; the electrical contact chip H 2200 is precisely positioned relative to the ink supplying member H 1500 by placing, in the terminal positioning holes 1309 , the two terminal positioning pins H 1515 on the back surface of the ink supply unit H 1003 . That is, as the electrical contact chip H 2200 is precisely positioned relatively to the back surface of the ink supplying member H 1500 , and fixed thereto, the terminal connective pins H 1516 of the ink supply unit H 1003 are put through the terminal connective holes 1310 . Then, the terminal connective pins H 1516 are crimped to fix the electrical contact chip H 2200 to the ink supply unit H 1003 . The fixing method does not need to be limited to the abovedescribed one; a method other than the abovedescribed one may be used.
The ink supply unit H 1003 and recording unit H 1002 are joined with each other as described above, and the connective portions of the ink container holder H 2000 are fitted into the connective holes of the ink supplying member H 1500 , completing thereby the recording head portion H 1001 , which is shown in FIG. 7 .
(2) Ink jet Recording Apparatus
The ink jet recording apparatus is such a recording apparatus that forms an image on a sheet of recording paper, by moving back and forth its recording head cartridge in a primary scan direction (carriage movement direction), for example, while controlling the movement of the sheet of recording paper by the control circuit of the apparatus.
FIG. 8 is a block diagram of the control circuit of the ink jet recording apparatus in this embodiment, and shows the general structure of the circuit. In the drawing, a controller 200 is the primary controller. It has a CPU 201 (Central Processing Unit), which is in the form of a microcomputer. The controller 200 also has: a ROM 203 (Read Only Memory) in which fixed data, such as programs and tables, are stored; and a RAM 205 (Random Access Memory) having the areas used for such an operation as the development of image formation data. A host apparatus 210 is an image data source (which may be a computer which forms and processes data for images to be printed, reader for reading original images, etc.). Image formation data, commands related to image formation, status signals, etc., are transmitted between the host apparatus 210 and ink jet recording apparatus through an interface 212 (I/F). An electric power switch 222 , a recovery switch 226 (for initiating recording head suctioning operation to restore recording unit performance), etc., are parts of a group of switches, which are usable by an operator (user) to input operator's commands. A sensor group 230 is for detecting the state of the ink jet recording apparatus. It includes: a home position sensor 30 for detecting whether or not the recording head is in its home position; a paper end sensor 33 for detecting whether or not a printing medium (sheet of recording paper or the like) is present; and a temperature sensor 234 disposed in a position suitable for detecting the ambient temperature. A head driver 240 is a driver for driving ink jetting heaters 25 of the printing head 1 in accordance with print data, etc. It has: a shift register which aligns the print data with ink jetting heaters 25 ; and a latching circuit which latches print data with the ink jetting heaters 25 with proper timing. It also has: a logic circuit which activates ink jetting heaters 25 in synchronism with driving timing signals; and a timing setting portion which sets proper timing (ink jetting timing) for driving the electrothermal transducers to form each ink dot on a proper point on the recording medium. A motor driver 250 is a driver for driving a primary scan motor 4 . A secondary scan motor 34 is the motor for conveying the recording sheet (in the secondary scan direction). The motor driver 270 is a driver for the secondary scan motor 34 . A recording sheet feeding motor 35 is a motor for feeding one of recording sheets in an automatic sheet feeder, into the main assembly of the ink jet recording apparatus, or separating the recording sheet to be fed into the main assembly, from the rest. A motor driver 260 is for driving the recording sheet feeding motor 35 .
Next, the formation of data for jetting ink onto a sheet of recording paper in order to maintain the ink jet recording apparatus in terms of ink jetting performance, that is, an operation which is not intended for image formation, will be described. The data for jetting ink to maintain the ink jet recording apparatus in performance is computed by the CPU 201 , or stored in the ROM 203 in advance. The data are developed, along with print data, in the RAM 205 . The developed maintenance data are transferred to the head driver, as are the print data, to activate the ink jetting heaters to jet ink.
The pattern, in which dots are to be formed on a sheet of recording medium when ink is jetted for the maintenance of the ink jet head in terms of performance, is computed by the CPU 201 , or it is a preset pattern in one of the control programs. The preset pattern may be modified to satisfy one or more of various conditions. The unsatisfactory jetting of ink, which is attributable to the increase in the ink viscosity, is affected by the properties of the ink used for printing, in particular, moisture retaining ability, the ink type (dye-based ink or pigment-based ink, for example), and the temperature of the environment in which the ink jet recording apparatus is operated. Thus, the preset pattern may be modified in response to one or more of these factors. The ambient temperature is detected by the temperature sensor 234 , with which the ink jet recording apparatus is provided. The recording data for jetting ink for the maintenance of the ink jet head, that is, the jetting of ink, which is not intended for image formation, need to be such that the dots which the ink droplets jetted for the maintenance form on a sheet of recording paper as they land on the recording sheet, will be as low as possible in visibility. Thus, the pattern in which dots are to be formed by the ink droplets jetted for the maintenance is desired to be such that each ink dot does not overlap with the immediately adjacent ink dot, and also, that ink dots do not align in sequence in the direction parallel to the columns of nozzles. That is, the data for jetting ink for maintenance is desired to be such that the ink dots formed from the ink droplets jetted for maintenance that land on the recording sheet will scatter as they land on the recording sheet in such a pattern that the dots do not overlap at all. The larger the dot intervals, the better. Further, it is desired that when ink is jetted for maintenance, it is jetted so that the dots which the ink will form do not show periodicity. Thus, when the recording head is driven for maintenance, it is not continuously driven at the maximum frequency in terms of the primary scan direction. Instead, it is driven in such a manner that dots are formed with intervals of several millimeters to slightly longer than 10 mm, in terms of the widthwise direction of the recording sheet, and also, so that ink will not be simultaneously jetted from adjacent two nozzles in terms of the direction parallel to the column of nozzles, while a single ink droplet is jetted per nozzle. The number of ink droplets jetted per moving range of the recording head during a maintenance operation is in a range of 3-15. It has no relation with the print data; the ink droplets are jetted in a fixed pattern.
Table 1 is a summary of the results of the evaluation, in terms of visibility, of the dots formed by each of the inks when the ink was jetted for maintenance, that is, when the ink was not jetted for image formation. The table shows the relationship among volumes (ink droplet size) of ink droplets jetted for maintenance, ink colors, and visibility of the dots formed by the ink droplets jetted for maintenance. The dot diameters shown next to the ink droplet sizes, one for one, are the sizes of the ink dots formed on a sheet of coated paper for ink jet recording, and are given for reference.
TABLE 1
Ink droplet
5.0 pl
3.0 pl
1.5 pl
1.0 pl
Dot dia. (μm)
47
35
27
22
Cyan
N
F
G
G
Magenta
N
F
G
G
Dye Blk
N
F
G
G
Yellow
F
G
G
G
L. Cyan
F
G
G
G
L. Mag.
F
G
G
G
Table 1 shows the evaluation, in terms of visibility, of the dots formed when the various inks were jetted for maintenance at a ratio of roughly 3-6 ink droplets per raster. Here, visibility means how inconspicuous were the dots formed by the ink droplets jetted for maintenance, that is, the ink droplets which were not intended for image formation. More specifically, the inconspicuousness of the dots was evaluated by subjects whose eyesight is in a range of roughly 1.0-1.5, from a distance of roughly 20 cm. “G” indicates that the dots on the recording sheet are satisfactorily low in visibility (inconspicuous), and “F” indicates that they are middle in visibility. “N” means that the dots are unsatisfactorily high in visibility (conspicuous). The recording papers used for the evaluation of the dots in terms of visibility are paper made of ordinary wood pulp. The tests provided results which are easily predictable. That is, the smaller the ink droplet size, and the higher the ink in brightness, the lower in visibility (more inconspicuous) were the dots formed on the recording paper by the ink droplets jetted for maintenance. At the same time, the tests brought a new discovery (knowledge) that the visibility of a dot is affected by the color of ink. Based on this discovery (new knowledge), it is desired that in the case of yellow ink (which is a naturally light color), light cyan ink, and light magenta ink, the ink droplet size is no more than roughly 4 pl, whereas in the case of cyan ink and magenta ink (which are naturally darker inks) and dye-based black ink, the ink droplet size is no more than roughly 2 pl. However, ink droplet size may be selected according to the performance of the ink, the rate at which each ink bleeds on the recording paper, and the like factors. The ink droplet size for a recording head, and the structure and arrangement of the ink jetting nozzles (columns of nozzles) for a recording head for each color, are determined according to the visibility of the dots formed by the ink droplets jetted for maintenance.
In this embodiment, three inks different in color are used, and the inks are jetted out in two different sizes. That is, an ink of lighter color is jetted in a relatively large size, and two inks of darker color are jetted in a relatively smaller size. More specifically, the ink droplet size for the ink of light color is no more than roughly 4 pl, and the ink droplet size for the inks of darker color is no more than roughly 2 pl. In addition, the number of nozzles per column of nozzles for the ink of lighter color is greater than that for the ink of darker color. The tests were carried out to evaluate in visibility the dots formed by the ink droplets jetted for maintenance by the ink jet head structured as described above to confirm the validity of this structural arrangement.
FIG. 9 is a schematic plan view of the second recording chip H 1101 of the recording head of the first embodiment of the present invention, as seen from the side where the ink jetting openings of the nozzles are located. It shows the ink droplet size and nozzle column arrangement for each ink. The three inks to be jetted for maintenance are cyan, magenta, and yellow inks. The second recording chip H 1101 is provided with five pairs of columns of nozzles, and also, three ink containers H 1900 for three color inks, one for one. Obviously, there is no problem even if the ink containers are not independent from each other.
The first preferred embodiment of the present invention is characterized in that two columns of nozzles (columns of small nozzles), which are roughly 1.5 pl in ink droplet size, are assigned to each of the cyan and magenta inks. More specifically, the opening of each small nozzle has a proper size for jetting ink droplets which are roughly 1.5 pl in volume. The ink jet head in this embodiment has 512 nozzles per column of nozzles. However, it is not problematic even if the number of nozzles per column of nozzle is different from that in this embodiment. Further, the order in which the columns of nozzles for each ink are arranged in terms of the primary scan direction of the recording head is: pair of columns of nozzles 401 for first cyan ink, pair of columns of nozzles 501 for first magenta ink, pair of columns of nozzles 402 for second cyan ink, and pair of columns of nozzles 502 for the second magenta ink, listing from the upstream side in terms of the primary scanning direction. Further, a pair of columns of nozzles 300 (columns of large nozzles) for the first yellow ink, which are roughly 3.0 pl in ink droplet volume are on the downstream side of the second magenta ink columns 502 . The opening of each large nozzle has a proper size for jetting ink droplets which are roughly 3.0 pl in volume. The nozzle count of each column of large nozzles, namely, the column 300 of nozzles for yellow ink is 512 , whereas the nozzle count of each column of small nozzles, namely, each of the cyan columns of nozzles 401 and 402 for cyan ink, and each of the columns 501 and 502 of nozzles for magenta ink, is 1,024. That is, this embodiment is also characterized in that the nozzle count of the column of small nozzles is twice that of the column of large nozzles.
Further, the pitch of each of the pair of columns of large nozzles is 600 dpi. That is, the nozzles of each column of large nozzles are positioned with intervals (pitch) of roughly 0.0423mm (25.4 mm/60). Further, the two columns are displaced relative to each other in the direction parallel to the columns by a distance equal to one half the interval (pitch), so that, as seen from the direction parallel to the columns, the nozzles are disposed in a zig-zag pattern. Thus, the combined pitch of the pair of columns of large nozzles is 1,200 dpi. However, the nozzle count and pitch for the column of large nozzles do not need to be limited to those mentioned above. Further, the pitch of each of the pair of columns of small nozzles, that is, the pair of columns of nozzles for each of the cyan and magenta inks, which is smaller in ink droplet size, is roughly 2,400 dpi, in other words, roughly 0.011 mm in nozzle opening interval. That is, this embodiment is also characterized in that the combined pitch of the pair of columns of small nozzles for each of the inks of light color is 2,400 dpi. Shown in FIG. 10 are the details of the abovementioned nozzle arrangement.
The recording head cartridges structured as described above were evaluated in terms of the visibility of the dots formed by the ink droplets jetted for maintenance. The method used for the evaluation is the same as that described previously. That is, ink droplets were jetted for maintenance at a rate of roughly 3-6 droplets per raster, on a sheet of recording paper, and the dots formed by the ink droplets were evaluated in terms of their visibility. The sheets of recording paper used for the evaluation were sheets of recording paper formed of ordinary pulp. The results were as follows: the dots formed on the sheet of recording paper by cyan, magenta, and yellow inks were all satisfactorily low in visibility, that is, m in the evaluation standard described previously. Moreover, the test images printed immediately after the completion of the operation in which ink was jetted for maintenance were satisfactory. That is, there was no sign that ink was erroneously jetted.
Images which appear significantly less grainy than the images formed with the use of a conventional ink jet recording head while maintaining it with the use of a conventional recording head maintaining method can be formed by structuring an ink jet head so that cyan and magenta inks can be jetted in a droplet size which is small enough for the dots formed by the droplets jetted for maintenance are satisfactorily low in visibility (inconspicuous). More concretely, it is possible to form graphic images, which do not appear as grainy, across their gray halftone areas, and/or color halftone areas, as the images formed by a conventional ink jet recording apparatus while a maintenance operation is carried out, and also, photographic images which do not appear as grainy, across the shadowy areas, and highlighted areas, such as blue sky areas and human skin areas, as the image formed by a conventional ink jet recording apparatus while a maintenance operation is carried out.
Further, structuring an ink jet head so that the number of the columns of nozzles for the ink which is to be jetted out in a smaller size compared to the dot interval is twice or more of that of the columns of nozzles for the ink which is to be jetted out in a larger size compared to the dot interval, makes it possible to print a higher speed than a conventional ink jet head, because an ink jet head structured as described above is greater in the number of image formation dots which can be deposited on a sheet of recording paper per scanning movement of the recording head cartridge. At this time, the expression of “greater in the number of image formation dots which can be deposited” will be explained with reference to FIG. 11 .
In FIG. 11 , ( a ) and ( b ) are schematic drawings of the matrix in which dots are formed by the recording head in this embodiment per scan. More specifically, in FIG. 11 , ( a ) shows the pattern in which ink dots are formed on the recording paper by a recording head which has only a single column of nozzles per ink (cyan ink, for example) when the resolution is 1,200 dpi and ink droplet size is 1.5 pl. In this case, the dot diameter is smaller than the dot interval of the recording head. Thus, the spaces among the dots are conspicuous. In comparison, in FIG. 11 , ( b ) shows the pattern in which ink dots are formed on the recording paper by a recording head in this embodiment, which has two columns of nozzles per ink (for example, cyan ink). In this case, a group of dots D 1 and a group of dots D 2 are formed, in the same area corresponding to each raster, by the ink droplets jetted from the column 401 of nozzles for the first cyan ink, and the ink droplets jetted from the column 402 of nozzles for the second cyan ink, respectively. Therefore, the spaces among the dots on the recording paper are significantly smaller than those shown in drawing (a) of FIG. 11 ; the dots are formed with the presence of significantly smaller spaces among them. Thus, a single scan by this recording head can achieve a satisfactory high level of density.
Further, keeping the droplet size of such an ink as yellow ink relatively large, for example, 3.0 μl, yields the following effects: First, it reduces the amount of energy necessary for jetting the ink, and therefore, enables the recording head to retain heat more efficiently, contributing to the increase in print throughput. In addition, when the ink is jetted for maintenance, onto the recording paper, that is, even when ink jetting is not intended for image formation, the dots formed on the recording paper are satisfactorily low in visibility. Therefore, the operation for maintaining the recording head can be increased in speed. Thus, the print throughput drastically increases.
In this embodiment, the resolution of the dots formed by smaller ink droplets is twice that of the dots formed by larger ink droplets. However, there is no problem even if the resolutions different from those in this embodiment are used. Further, regarding the nozzle column count, the number of the columns of nozzles which jet smaller ink droplets may be three or four times the number of the columns of nozzles which jet larger ink droplets. In such a case, the size of a smaller ink droplet may be ⅓ or ¼ of the size of a larger ink droplet. Further, a recording head may be structured so that, instead of providing a recording head with twice or more number of columns of nozzles for jetting smaller ink droplets than the number of column of nozzles for jetting larger ink droplets, the nozzle count of each column of nozzles for jetting smaller ink droplets is greater than the nozzle count of a column of nozzles for jetting large ink droplets.
Further, there is no requirement regarding the order in which columns of nozzles, which are different in the color of the ink they jet, are arranged.
Embodiment 2
The recording head in this embodiment is superior to the recording head in the first embodiment, in terms of image quality, and also, is higher in print throughput than the recording head in the first embodiment.
FIG. 12 is a plan view of the surface of the second recording chip H 1101 of the recording head cartridge in the second embodiment of the present invention, as seen from the side where nozzle openings are located, and shows the ink droplet sizes and the arrangement of the columns of nozzles different in the color of the ink they jet. This embodiment is the same as the first embodiment, except for the arrangement of the columns of nozzles. Thus, only the arrangement of the columns of nozzles in this embodiment will be described.
The second embodiment of the present invention can be characterized as follows: The recording head in this embodiment is also provided with two columns of small nozzles for each of the cyan and magenta inks, as is the recording head in the first embodiment, but is different in the arrangement of the columns of nozzles from that in the first embodiment. Referring to FIG. 12 , listing from the lefthand side, a pair of columns of nozzles 401 for the first cyan ink, a pair of columns of nozzles 501 for the first magenta ink, a pair of columns of nozzles 300 for the first yellow ink, a pair of columns of nozzles 502 for the second magenta ink, and a pair of columns of nozzles 402 for the second cyan ink, are positioned as listed. That is, the pair of columns of large nozzles are placed in the middle, and two sets of two pairs of columns of small nozzeles are symmetrically placed on the left- and right-hand sides of the pair of columns of large nozzles. As long as the number of the pairs of columns of small nozzles is even, the columns of small nozzles can be arranged so that the set of the columns of nozzles on the left-hand side relative to the central pair of columns of nozzles (large nozzles), and the set of columns of nozzles on the right-hand side, are symmetrically positioned with respect to the central pair of columns of nozzles, in terms of nozzle size and ink color. The ink nozzle count per column of small nozzles, ink nozzle count per column of large nozzles, nozzle column count, nozzle opening pitch of each column of small nozzles, nozzle opening pitch of each column of large nozzles, etc., are the same as those of the recording head in the first embodiment.
The results of the tests carried out to evaluate the visibility of the dots formed by the ink droplets jetted for maintenance by the recording head cartridge in this embodiment are as follows. The evaluation method is the same as that used for evaluating the recording head cartridge in the first embodiment. The cyan ink dots, magenta ink dots, and yellow ink dots on the recording paper were all satisfactorily low in visibility, being “G” with reference to the same evaluation standard as that used for evaluating the recording head cartridge in the first embodiment. Further, the test images printed immediately after the completion of the operation in which inks were jetted for maintenance were satisfactory, showing no signs of erroneous jetting of ink.
Not only does this embodiment have the same effects as those which the first embodiment has, but also, it can prevent the problem that an image printed at a high speed while scanning only once each area of a sheet of recording paper, which is equivalent to a single raster, appears nonuniform because of the difference between the areas of the image, which were formed when a recording head is moved in one direction, and the areas of the image, which were formed when the recording head is moved in the other direction (bidirectional printing).
More concretely, when forming an image made of multiple areas different in color (for example, red, blue, green, and also, gray effected by depositing the inks of preceding three colors), the order in which color inks are deposited on the recording paper when the recording head is moved in one direction is the same as that in which the color inks are deposited on the recording paper when the recording head is moved in the other direction. Therefore, the problem that the areas of an image, which were formed by depositing inks on the recording sheet while the recording head was moved in one direction, appear different in tone from the areas of the image, which were formed by depositing inks on the recording sheet while the recording head was moved in the other direction, does not occur.
At this time, the structure of the recording head in this embodiment in terms of the arrangement of columns of nozzles will be described in detail, along with a modified version of the recording head in this embodiment, which also can offer the same effects as those offered by the recording head in this embodiment. In FIGS. 13 , ( a ) and ( b ) show in detail the columns of nozzles shown in FIG. 12 .
In the case of the nozzle arrangement shown in detail in (a) of FIG. 13 , the nozzle pitch of each of the columns of nozzles which are smaller in ink droplet size, that is, the columns of nozzles for jetting cyan and magenta inks, is 2,400 dpi, as they are in the first embodiment, whereas in the case of the nozzle arrangement shown in detail in (b) of FIG. 13 , the recording head is structured so that the corresponding nozzles, in terms of the direction parallel to the columns of nozzles, in the column 401 of nozzles for the first cyan ink, column 501 of nozzles for the first magenta ink, column 402 of nozzles for the second cyan ink, and column 502 of nozzles for the second magenta ink, align in the primary scan direction of the recording head.
In the case of the recording head in this embodiment, the pair of columns of larger nozzles is positioned in the center of the recording head, and the two pairs of columns of smaller nozzles are positioned on each side of the pair of columns of larger nozzles, in such a manner that the two sides become symmetrical in terms of ink color. Therefore, the order in which color inks are deposited on the recording paper when the recording head is moved in one direction is the same as the order in which color inks are deposited on the recording paper when the recording head is moved in the opposite direction. Therefore, even though the recording head is structured so that the corresponding nozzles in the first pair of columns of nozzles and the second pair of columns of nozzles align in the primary scan direction, the problem that even though the areas of an image printed while a recording head is moved in one direction is slightly different in tone from the areas of the image printed while the recording head is moved in the opposite direction, does not occur. In other words, this embodiment can afford more latitude in the nozzle placement in each column of nozzles than the first embodiment. Incidentally, in this embodiment, the droplet size of yellow ink, that is, the ink which is low in the visibility of the dots it forms when it is jetted for maintenance, is desired to be no more than roughly 4.5 pl as it is in the first embodiment. Further, from the standpoint of the visibility of the dots formed when the cyan and magenta inks are jetted for maintenance, the droplet size for cyan and magenta inks are desired to be no more than roughly 2.5 pl. However, the ink droplet size may be selected according to the performance of the ink, rate at which each ink bleeds on the recording paper, and the like factors. These are the features which characterize this embodiment, which is for providing a recording head capable of forming images which are satisfactorily low in the visibility of the dots formed by the ink droplets jetted for maintenance, satisfactorily high in image quality, and satisfactorily high in printing speed.
Embodiment 3
Next, another embodiment of the present invention, which can further improve a recording head in terms of the quality of a photographic image, that is, an image required to be more precise in detail, will be described.
In FIGS. 14 , ( a ) and ( b ) are drawings for describing the third preferred embodiment of the present invention. More specifically, they are schematic plan views of the surface of the second recording chip H 1101 in this embodiment of the present invention, as seen from the side where nozzle openings are located. They show the ink droplet size, and the order in which the columns of nozzles for various inks different in color are positioned. This embodiment also is the same as the first embodiment except for the nozzle column arrangement, as is the second embodiment.
In FIG. 14 , ( a ) is a plan view of the surface of the second recording chip H 1101 in this embodiment, as seen from the side where nozzle openings are located. This recording chip has two pairs of columns of nozzles for the black ink, in addition to the same ink columns of nozzles as those of the recording chip in the second embodiment. The black ink used by this recording chip is dye-based black ink for forming photographic images. The size of the dye-based black ink jetted from the columns 601 and 602 of nozzles for the black ink is roughly 1.5 pl. The nozzle count of each column of nozzles for the black ink is the same as the nozzle count of each column of nozzles of the recording chip in the first embodiment. The first recording chip H 1100 in this embodiment uses pigment-based black ink. However, the pigment-based black ink is unlikely to permeate into such recording paper as coated paper, high gloss paper, etc., which were specifically created for recording high quality images, for example, photographic images. Therefore, when the recording head in this embodiment is used for recording on recording medium for high quality images, pigment-based black ink is not used. That is, when recording photographic images, black color is composed by mixing color inks (so-called composite black). If a recording chip is structured like the one in this embodiment, black-and-white images can be printed at an appropriate level of density, on a sheet of ordinary paper, by the pigment-based black ink for which a pair of black ink columns of nozzles is provided. In addition, the dye-based ink can be used when printing photographic images on a sheet of recording paper for high quality images. The usage of dye-based inks along with the recording chip in this embodiment can yield photographic images which are higher in density and contrast. In other words, this embodiment makes it possible to print images of higher quality at a higher speed than a recording chip in accordance with the prior art.
In FIG. 14 , ( b ) is a plan view of the surface of a modified version of the second recording chip H 1101 in this embodiment, as seen from the side where nozzle openings are located. This recording chip has two pairs of columns of nozzles for jetting dye-based black ink, two pairs of columns of nozzles for jetting light cyan ink, and two pairs of columns of nozzles for jetting light magenta ink, in addition to the columns of nozzles which the recording chip in the second embodiment has. The light cyan ink and light magenta ink used in this embodiment are such cyan and magenta inks that are roughly ⅓-⅙ in density. The size of an ink droplet jetted from the columns 601 and 602 of the nozzles for dye-based black ink is roughly 1.5 pl, and the size of an ink droplet jetted from the columns 400 and 500 of the nozzles for light cyan ink and light magenta ink, respectively, is roughly 3.0 pl. Also shown in Table 1 are the visibility level of the dots formed by the light cyan ink droplets, and that of the dots formed by the light magenta ink droplets, indicating that the dots formed by the inks of light color (inclusive of yellow ink) tend to reduce in visibility as they are reduced in density. Therefore, the droplet size in which the inks of light color are jetted may be larger compared to the droplet size in which inks of dark color, such as cyan, magenta, dye-based black ink, etc., which are higher in visibility, (conspicuous) are jetted. Incidentally, the light cyan ink and light magenta ink used by the recording chip in this embodiment are no more than 1.4% in the weight-based density of coloring material. By determining the dot size for the light inks for printing images of high quality, based on the visibility of the dots formed by the ink droplets jetted for maintenance, as in this embodiment, it is possible to print high quality images at a high speed while jetting ink droplets for maintenance, that is, the ink droplets which are not intended for image formation, on a sheet of recording paper.
In FIG. 14 , ( b ) shows the recording head in this embodiment, which has three second recording chips H 1101 arranged side by side. There is a tendency that the greater the number of columns of nozzles per recording chip, the lower the yield of recording chip. However, structuring a recording chip as it is in this embodiment makes it unnecessary to significantly increase the number of columns of nozzles per recording chip, being therefore less likely to reduce the recording chip yield. Further, referring to FIG. 15 , in this embodiment, the recording head is provided with three second recording chips H 1101 , and each of the three recording chips H 1101 is provided with three pairs of columns of nozzles. Moreover, one column of nozzles of each of the lateral pairs of columns of nozzles of each recording chip H 1101 is displaced relative to the other columns of nozzle, in the direction parallel to the columns of nozzles, by a distance equal to 1/2 the nozzle interval of the column, that is, a distance equivalent to 2,400 dpi, making it possible to form dots at a resolution of 2,400 dpi when inks of light color, that is, the inks to be jetted in a smaller droplet size, are jetted. Further, the three second recording chips H 1101 are arranged in parallel without being deviated relative to each other in the direction parallel to the columns of nozzles. Thus, this embodiment makes it possible to select the ink droplet size of the second recording chip, according to the visibility of the dots formed by the ink droplets jetted for maintenance, that is, the ink droplets which are not intended for image formation. It also makes it possible to provide a recording head, the columns of nozzles of which are symmetrically arranged, as those of the recording head in the second embodiment, to reduce the occurrence of tone deviation.
Recording head cartridge structured as described above was evaluated in terms of the visibility of the dots formed by the ink droplets jetted for maintenance. The evaluation method is the same as the one described above. The evaluation was “G” with reference to the evaluation standard described above, for all the dots formed on a sheet of recording paper using inks of all colors and densities. Further, the images of test patterns printed immediately after the completion of a maintenance operation were all satisfactory, indicating that erroneous jetting of ink did not occur.
While the invention has been described with reference to the structures disclosed herein, it is not confined to the details set forth, and this application is intended to cover such modifications or changes as may come within the purposes of the improvements or the scope of the following claims.
This application claims priority from Japanese Patent Application No. 334467/2007 filed Dec. 26, 2007, which is hereby incorporated by reference herein. | An ink jet recording head includes a large nozzle array including a plurality of ejection outlets for ejecting ink and a small nozzle array including a plurality of ejection outlets, each having an opening area smaller than an opening area of ejection outlets of the large nozzle array. The ink jet recording head is mountable to an ink jet recording apparatus which is capable of causing the ink jet recording head to eject ink for a purpose of maintenance of the ink jet recording head without image formation on a recording material, the large nozzle array is supplied with light ink such as yellow, light cyan or light magenta ink, and the small nozzle array is supplied with dark ink such as cyan, magenta or black ink. The number of ejections of the dark ink is greater than the number of ejections of the light ink. | 73,109 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the ball type constant velocity joints. In particular, the invention relates to a ball assembly in the form of a sphere divided up into a plurality of rollers (rolling elements) and a common shaft that holds the rollers. The purpose of the invention is to reduce the friction loss and wear of the constant velocity joints.
2. Description of the Prior Art
Universal joints (Cardan joint or Hooke joint) have been used for transmitting a driving torque and spin motion from one propeller shaft to another at an arbitrary articulation (joint) angle between the two shafts. Universal joints comprise a cross-shaped spider as a torque-transmitting member, and two Y-shaped end yokes each at end of the shafts. Universal joints lack the constant-velocity characteristic, because the spider is not positioned on a homokinetic plane (bisecting angle plane or constant velocity plane) when the joint is at a non-zero articulation angle. As a result, universal joints suffer from a torsional vibration problem that aggravates as the articulation angle increases.
Constant velocity joints solve this problem by offering a virtually zero variation of the spin speed across the input and output shafts. Most of the constant velocity joints use a plurality of torque-transmitting balls that are solid steel spheres. The types of the constant velocity joints that use torque-transmitting balls are the Rzeppa joint [U.S. Pat. No. 2,046,584 filed July 1924 by A. H. Rzeppa], the undercut free joint [U.S. Pat. No. 3,879,960, filed July 1975 by H. Welschof et al], the cross groove joint [U.S. Pat. No. 2,322,570 filed June 1943 by A. Y. Dodge], and the double offset joint [U.S. Pat. No. 1,975,758 filed October 1934 by B. K. Stuber]. Any type of constant velocity joint comprises the inner race (inner joint part), outer race (outer joint part), ball cage (retainer) and the balls. The outer race usually forms a bell-shaped member that comprises a shaft, a base, an aperture and outer ball grooves (tracks) that are machined on its bore surface. The inner race forms a hub that comprises a shaft and inner ball grooves that are machined on its outer surface. The ball cage is positioned between the outer race and the inner race, and comprises circumferentially distributed cage windows (pockets) that hold the balls in the central plane of the ball cage. The inner and outer groove pairs form a special kinematic arrangement that steers (drives) the balls to the homokinetic plane.
But constant velocity joints suffer from five distinct disadvantages: 1) they lose some amount of power to sliding friction; 2) the frictional heat could produce high temperature; 3) this high temperature limits the permissible operating speeds and loads; 4) the friction decreases the durability and life of the joints; and 5) the friction, when coupled with a certain operating condition, could lead to a binding (friction lock) problem. See for example, “Universal Joint and Driveshaft Design Manual,” The Society of Automotive Engineers, Inc. 400 Commonwealth Drive, Warrendale, Pa. 15096, ISBN 0-89883-007-9, 1979, pp. 100; and Philip J. Mazziotti, “Dynamic Characteristics of Truck Driveline Systems,” The Eleventh L. Ray Buckendale Lecture, The Society of Automotive Engineers, Inc., SP 262, pp. 21.
From the viewpoint of kinematics, the balls of a constant velocity joint cannot have a true rolling condition, because the grooves are not concentric but generally intersect to each other. From the viewpoint of dynamics, each ball is steered (located) to the bisecting plane by the combined action of the inner groove, the outer groove and the cage window. This means that there are at least three contact points on a ball, when a constant velocity joint is spinning under the torque load: the ball to inner groove contact, the ball to outer groove contact, and the ball to cage window contact. Obviously, the ball cannot retain a true rolling condition at all three contact points at the same time. Therefore, some or all of the contact points on a ball cannot but undergo a sliding contact or friction.
Previous attempts by others to reduce the friction problem of constant velocity joints have employed special lubricant. These attempts, however, have not proven to completely solve the friction problem, because such measure can only reduce the friction coefficient value.
BRIEF SUMMARY OF THE INVENTION
It is an object of the present invention to provide torque-transmitting balls for constant velocity joints, while reducing or eliminating the sliding friction of the balls against the surfaces of its mating inner groove, outer groove, and the cage window.
The present invention for a “multi-roller” ball provides the foregoing object, and thus offers significant improvements over the prior art. As its name implies, the multi-roller ball assembly has a plurality of sub-rollers, each of which contacts and rolls independently on its mating outer groove and inner groove. None has embodied the concept of the multi-roller ball to cause its each sub-roller to roll independent from each other, and thus to cause the reduction or elimination of the sliding friction problem in constant velocity joints.
The multi-roller ball offers the advantages of enabling any ball-type constant velocity joints to have a reduced internal friction loss; to have a smooth articulation and plunge; to have a lower operating temperature; to have an increased durability and life; and to have a higher operating speed and larger torque capacity.
The multi-roller ball enjoys these advantages because it has a plurality of sub-rollers rotating independently from each other around a common shaft called the roller shaft. Therefore, in a constant velocity joint receiving a torque load, one sub-roller can roll freely on an outer groove, while another sub-roller rolls on an inner groove. This multi-roller construction relieves the ball assembly from a harmful sliding friction at its rolling contact points. In order to maintain the orientation of the roller shaft along the circumferential direction of the cage window, a slide shaft is provided in such a manner that it can slide along the shaft hole through the axis of the roller shaft and that the lugs at both ends of the slide shaft engage the cage-web grooves that are machined at either sides of the cage webs towards the radial direction. Thus, the multi-roller ball achieves the implementation of the objectives mentioned above in a commercially viable component that is simple and inexpensive enough to be easily applicable to any existing ball-type constant velocity joints.
Further objectives and advantages of the multi-roller ball will become apparent from consideration of the drawings and descriptions that follow. Therefore, to the accomplishment of the objectives described above, this invention consists of the features hereinafter illustrated in the drawings, fully described in the detailed description of the preferred embodiments and particularly pointed out in the claims. However, such drawings and descriptions disclose but some of the various ways in which the invention may be practiced.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 is a perspective view of a prior-art constant velocity joint.
FIG. 2 shows a prior-art constant velocity joint under a torque load in a partially enlarged central plane section, illustrating the contact points of a ball against the inner and outer grooves.
FIG. 3 is a partially enlarged radial view of a prior-art constant velocity joint, showing the contact between the ball and the cage window (the outer and inner races are not shown).
FIG. 4 shows a multi-roller ball assembly in a longitudinal (spin-axis) section, illustrating the assembly of the two half-spherical sub-rollers, the roller shaft, and the slide shaft.
FIG. 5 shows a multi-roller ball assembly in a longitudinal (spin-axis) section, revealing the first and second needle bearings disposed between the roller shaft and the two half-spherical sub-rollers.
FIGS. 6A and 6B are the front and side views of the half-spherical sub-roller.
FIGS. 7A and 7B are the front and side views of the roller shaft.
FIG. 8 shows an actual use of a multi-roller ball in a constant velocity joint in a partially enlarged central plane section, revealing the contact points of the half-spherical sub-rollers against the inner and outer grooves.
FIG. 9 shows a partially enlarged radial view of my invention in an actual use with a constant velocity joint (the outer and inner races are not shown), revealing the contacts between the slide shaft and the cage.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings, where like parts are designated throughout with like numerals and symbols, FIGS. 1 through 3 depict a prior art constant velocity joint, presented herein as an illustration of its general construction and inherent problem. A constant velocity joint comprises the outer race (outer joint part) 1 , the inner race (inner joint part) 2 , the cage (retainer) 4 , and the balls 3 . The outer race shaft 5 is either integral to the outer race 1 , or securely connected to the outer race 1 by bolts or splines. The inner-race shaft 6 is typically connected to the inner race 2 by splines and retaining rings. The outer race 1 has a plurality of ball grooves (tracks) 1 a machined on its bore surface, while the inner race 2 has the pairing set of ball grooves (tracks) 2 a machined on its outer circumference surface. The positions of the balls 3 are restrained by the outer grooves 1 a and the inner grooves 2 a . The cage 4 has a plurality of the windows (pockets) 4 a that hold the balls 3 so that all of the balls 3 are located on the central plane of the cage 4 . The combined actions of the outer grooves 1 a , the inner grooves 2 a and the cage windows 4 a steer (locate) the balls 3 towards the constant velocity plane (bisecting-angle plane or homokinetic plane), yielding a constant velocity characteristics at any joint articulation angle.
FIG. 2 shows a partially enlarged central-plane section of a prior-art constant velocity joint that is receiving an external torque load 7 , 8 . The driving torque 7 onto the outer race 1 tries to rotate it to the counter-clock-wise direction, while the reaction torque load 8 onto the inner race 2 tries to rotate it to the clock-wise direction, resisting against the motion of the outer race 1 . This action and reaction produce the contact forces 9 , 10 onto the ball 3 . The contact force 9 from the outer groove 1 a to the ball 3 and another contact force 10 from and the inner groove 2 a to ball 3 squeeze the ball 3 . Thus each ball 3 has at least two contact points against its mating inner groove 2 a and the outer groove 1 a.
FIG. 3 is a partially enlarged radial view of a prior-art constant velocity joint; showing the contact condition between the cage 4 and the ball 3 . Note that the outer race 1 and the inner race 2 are omitted in FIG. 3 . Typically a cage 4 has a shape of two rings that are bridged together by the cage webs 4 d . In FIG. 3 , the cage window (pocket) 4 a is oriented such that its radial direction 12 c is out-of-paper direction, its tangential or circumferential direction 12 a is to the right-hand side, and its axial direction 12 b is parallel to the cage axis 13 . Each cage window 4 a has two cage flat surfaces 4 e , 4 f and another two web flat surfaces 4 g , 4 h . The distance between the two cage-flat surfaces 4 e , 4 f are generally called the window width. The window width is typically designed to be equal to or slightly larger than the diameter of the ball 3 . One of the main functions of the cage 4 is to push the ball 3 towards the homokinetic plane by generating the contact force 11 against the ball 3 . Thus at any given moment, a ball 3 has at least one contact point against one of the cage flat surfaces 4 e and 4 f . The distance between the two opposing web flat surfaces 4 g , 4 h are generally called the window length. The window length is typically designed to have an enough gap from the ball 3 in order to accommodate any circumferential movement of the balls 3 during the joint articulation.
Therefore, each ball 3 of a prior-art constant velocity joint has at least three contact points (forces): The first contact point is against the outer groove 1 a , the second one is against the inner groove 2 a , and the third one is against the cage window 4 a (in other words, the cage flat 4 e or 4 f ). As a result, it is inevitable that the ball 3 undergoes a sliding friction at some or all of the three contact points as the ball 3 is steered to another position. It is well known that this sliding friction could produce many problems such as the friction loss and the friction lock (binding), which could result in the heat generation and eventually the failure of the joint (durability problem). The goal of this invention is to prevent or reduce the friction-induced problems of the conventional ball-type constant velocity joints. This invention solves the problem by replacing the solid balls 3 with the multi-roller balls 20 that make the three contact points of each ball be independent from each other, thus positively eliminating the sliding friction.
FIG. 4 shows the longitudinal (spin-axis) section of a multi-roller ball assembly 20 in its preferred embodiment, illustrating the assembled state of its members. A multi-roller ball assembly 20 comprises two substantially half-spherical annular sub-rollers 22 , 23 , the roller shaft 24 , and the slide shaft 35 . In addition to these key components, sliding or needle bearings 33 , 34 for the sub-rollers 22 , 23 may be optionally employed for the enhanced performance as shown in FIG. 5 . Likewise, two retaining rings 29 , 30 may be employed at the either ends of the roller shaft 24 to hold the members together, facilitating the assembly of the multi-roller ball assemblies 20 into a constant velocity joint. The sub-rollers 22 , 23 can spin individually around the roller shaft 24 , allowing them to contact and freely roll on the outer groove 1 a and the inner groove 2 a of a constant velocity joint. The roller shaft 24 serves as a spindle for the sub-rollers 22 , 23 , and the aperture along its axis serves as a sliding guide for the slide shaft 35 . The slide shaft 35 maintains the spin axis orientation of the multi-roller ball 20 relative to the cage window 4 a by engaging its lugs 35 a , 35 b with the webs 4 d as will be explained further in FIGS. 8 and 9 . The slide shaft 35 takes any forces between the multi-roller ball 20 and the cage 4 . In addition, the slide shaft 35 allows the roller shaft 24 to slide longitudinally the slide shaft 35 so that a limited circumferential movement of the multi-roller ball assembly 20 relative to the cage window 4 a is accommodated. Since a multi-roller ball assembly 20 has a first and second sub-rollers 22 , 23 that spin independently from each other, it can positively eliminate or reduce any frictional sliding contact against the outer groove 1 a and the inner groove 2 a.
FIGS. 6A and 6B show the front and side views of the sub-roller 22 or 23 . Its center aperture 22 a that comprises the cylindrical bore surface 22 b and the tapered bore surface 22 c rides on the roller shaft 24 directly or via the bearing 27 or 28 . The spherical surface 22 d contacts against the outer race grooves 1 a or inner race grooves 2 a . The inner flat surface 22 e provides a gap against the adjacent sub-roller. The outer flat surface 22 f is intended for reducing the axial length (except the slide shaft 35 ) of the multi-roller ball assembly 20 so that the length of the cage window (the distance between 4 g and 4 h ) can be designed to be shorter. The outer flat surface 14 f can also serve as a thrust surface against the retaining rings 29 , 30 .
FIGS. 7A and 7B show the front and side views of the roller shaft 24 . Its cylindrical shaft surface 24 a and the tapered surface 24 b mate onto the bearings 33 , 34 or directly onto the sub-rollers 22 , 23 . The central ridge surface 24 c serves as a transition between the two neighboring tapered surfaces. The aperture 24 d is for the slide shaft 35 that can freely spin within or move along the aperture 24 d . The candidate materials for the roller shaft 24 are a solid metal, an oil-impregnated sintered metal, or any other sliding bearing material
FIG. 8 shows an actual use of a multi-roller ball 20 in a constant velocity joint in a partially enlarged central plane section, revealing the contact point of the sub-rollers 22 , 23 against the inner and outer grooves 1 a and 2 a . The multi-roller balls 20 can be used in conjunction with any type of constant velocity joint, except that the cage 4 should have additional cage web grooves 4 i machined to radial direction at each web flat surfaces 4 g and 4 h . The cage web grooves 4 i mate with the ends of the slide shaft 35 , constraining the orientation of each multi-roller ball assembly 20 with respect to the corresponding cage window 4 a . For most of the ball-type constant velocity joints, the inner and outer ends of cage web grooves 4 i are blocked by the outer race bore surface 1 b and the inner race outer surface 2 c . Therefore, the ends of the slide shaft 35 cannot disengage from the cage web grooves 4 i . However, in the case of the cross groove type constant velocity joints, the cage bore side of the cage web grooves 4 i should be closed so that the ends of the slide shaft 35 do not fall to the gap between the cage bore surface 4 b and the inner race outer surface 2 c.
FIG. 9 shows a partially enlarged radial view of my invention in actual use with a constant velocity joint (the outer race 1 and inner race 2 are not shown here), revealing the contacts between the ball assembly 20 and the cage 4 . As the cage 4 steers (moves) the multi-roller ball 20 , the cage web grooves 4 i push or pull the ball assembly 20 at the lugs 35 b , 35 c of the slide shaft 35 .
From the foregoing it will be apparent that an apparatus and method have been disclosed which are fully capable of carrying out and accomplishing all of the objects and advantages taught by this invention. As many as possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense. It will be understood that certain features and sub-combinations are of utility and may be employed without reference to other features and sub-combinations. This is contemplated by and is within the scope of the claims. | A constant velocity joint includes an outer joint member, an inner joint member, torque transmitting ball assemblies guided in pairs of tracks, and a cage having windows for receiving the ball assemblies and cage webs defined between the windows. Each ball assembly comprises a slide shaft having lugs at the ends, a roller shaft rotatably and slidably disposed on the slide shaft, and a first and second annular sub-rollers rotatably disposed on the roller shaft. Each of cage webs includes web grooves formed radially at the circumferential faces, engaging the lugs of the slide shaft, thereby allowing a limited radial movement of the ball assembly relative to the cage window, and transmitting any axial force to and from the ball assembly. The ball assemblies reduce the friction loss and wear of constant velocity joints by providing the sub-rollers that roll independently on the inner or outer tracks. | 19,472 |
TECHNICAL FIELD
[0001] The present disclosure generally relates to user-manipulable controls in software user interfaces. More specifically it expands upon a tabbed notebook control for switching among various views.
BACKGROUND
[0002] Tabbing controls are becoming increasingly pervasive in software User Interfaces (UIs). For instance, current-day web browsers such as Internet Explorer® (IE) and Firefox® have recently adding tabbing as a quick and convenient way to switch among open pages. Additionally, version 5.0 of LOTUS NOTES® included Inbox tabbing. Tab controls are also used in more general software applications to switch among views of different properties, etc. A major advantage of tabs is that they consume relatively little screen space, afford the ability to quickly navigate to another panel or view, and can utilize the same screen area to show many different views.
[0003] A shortcoming of tabs is that they are used ubiquitously in implementations which lack full user utility. For example, tab relational context doesn't provide a very rich UI structure. Furthermore, the majority of tabs only display text labels. Occasionally a status indicator has been added to a tab. Tab controls typically act as toggles, i.e., the entire tab's surface is a hot spot to click, hiding the contents of the previously active tab and displaying the contents of the tab that the user activates. These controls are toggles because the contents associated with a tab are either visible or hidden.
SUMMARY
[0004] The essence of this invention is to extend the single-select mutually-exclusive tab concept to include the ability to allow multiple tabs to be active simultaneously, while affording a simple method for the user to do so. The novelty of this invention includes:
a. Access to all combinations and permutations of the tab selections. The user can create combined views simply by activating the contents of multiple tabs. This would eliminate the need to create new tabs specifically to represent the combined views of other tabs. The views would be combined in an intelligent way by the software application and this method would differ depending on the application. b. Easy and natural way for user to “drill wider”—to a more end-to-end view as more tabs get selected. Just click another part (multi-select part) of another tab to select that tab to be added to the view. c. In a preferred embodiment, multi tabbing displays and provides access to additional information within the same view but with richer cross-set relationships.
[0008] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not necessarily restrictive of the present disclosure. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate subject matter of the disclosure. Together, the descriptions and the drawings serve to explain the principles of the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The novelty of the disclosure will be understood by those skilled in the art by reference to the accompanying figures in which:
[0010] FIG. 1 is a graphical user interface (GUI) of a current-day tab control illustrating the “Servers” tab being active and showing an error with the blade server in Slot 4 ;
[0011] FIG. 2 is a graphical user interface (GUI) of a current-day tab control illustrating the “Storage” tab being active and showing detail about applicable storage.
[0012] FIG. 3 is a graphical user interface (GUI) of a preferred embodiment of the present invention illustrating multi select control of the present invention; the contents of the “Servers” tab and the “Storage” tab have been intelligently combined by the application to present the user with a combined view of the two.
[0013] FIG. 4 is a graphical user interface (GUI) of a preferred embodiment of the present invention illustrating the utilization of tabs contextually related to each other;
[0014] FIG. 5 is a graphical user interface (GUI) of a preferred embodiment of the present invention illustrating the “Servers” tab and “Storage” tab intelligently combined by the application; and
[0015] FIG. 6 is a flow diagram of the utilization of multi tabbing of the present invention.
DETAILED DESCRIPTION
[0016] The present invention provides a method, apparatus and program storage device for multiple active tab functionality integrated into a tabbed view control on a software graphical user interface. One possible embodiment is illustrated in the accompanying drawings.
[0017] One embodiment involves troubleshooting hardware problems in a datacenter environment. The current invention would allow the user to combine individual views of hardware into a more integrated and holistic view, affording a better understanding of how individual components relate to one another.
[0018] Here is one example. Suppose there is a set of views, implemented in a tab view control that includes a view of servers and a view of storage. In FIG. 1 , it is apparent that there is an error associated the blade server in the 4th slot: “Web_Server — 3”, but the source of the problem remains unclear from this narrow perspective. The user then explores a bit more by clicking on the main part of the “Storage” tab, FIG. 1 (not the top of it, but where the text is). This replaces the previous view with a new view, as is the current art for tab view controls. The user now sees from the storage-only tabbed view that “Pool A” is full ( FIG. 2 ). The user now is wondering how and if “Pool A” relates to the web server blade, like could the problems be correlated? Using this multi-tab invention, the user could select the “Servers” tab in such a way as to NOT replace the “Storage” view. This could be highly surfaced on the tab itself. In the example below it is shown by the top colored bar on the tab, which is the multi-select touch point of the tab.
[0019] There are additional embodiments of this type of multi-select control, including but not limited to a check box on the tab, a drop-down selector as part of the tab, or via a right-click context menu choice for multi-tabbing ( FIG. 3 ).
[0020] Finally, ( FIG. 4 ) the user could next select the server to get an end-to-end view from the server to the storage and all the nodes in between, made possible and quickly accessible by this invention (one tabbed click from the point of context of either one of the single-select tab cases above, either from “Servers” or from “Storage”).
[0021] In a further embodiment of the present invention ( FIG. 5 ), two or more containers may be utilized, each containing multiple tab selectors. For example, a resource- or hardware-based tab group might span a particular dimension, as previously illustrated in FIGS. 1-4 (servers, storage, networking) and a more task-oriented tab group could span another. It would be possible to simultaneously activate or select a single tab in each container, thus creating a combined view in that manner. So, for example, the task-oriented tabs might have tabs for “Events”, “Health”, “Troubleshoot”, and the like. If properly designed, such a UI could surface fewer navigation nodes to the user than traditional UIs, and the task-oriented tabs matrixed with the resource-oriented tabs complement each other.
[0022] Referring to FIG. 6 , a method for providing a user interface 100 is depicted. Method 100 may define a first view comprising a representation of a first set of information, the first view displayable via the user interface 110 . Method 100 may associate the first view with a first tab of the user interface 120 . Method 100 may define a second view comprising a representation of a second set of information, the second view displayable via the user interface 130 . Method 100 may associate the second view with a second tab of the user interface 140 . Method 100 may receive a selection from the user via the user interface, the selection comprising at least the first tab and the second tab 150 . Method 100 may define a third view comprising a representation of at least a portion of the first set of information and at least a portion of the second set of information 160 . Method 100 may display the third view in response to the selection of at least the first tab and the second tab 170 .
[0023] This invention is applicable beyond the server-storage examples described above. Multi-select tabbing could also be used for map applications, with tabs for “Roads”, “Satellite”, and “Terrain”. Users could pick and choose one of more map tabs based on which map “layers” were most useful to them, and not have screen-wasteful and complicating “Hybrid” tabs to do that function. Another example would be for network management, with tabs for “Image”, “Tabular”, and “node-link”. Again, users could pick one or more tabs, with for example the “Tabular”+“node-link” tabs being selected could show a hybrid view of a node-link topology view intermixed with embedded mini tabular displays for particular nodes (e.g., event table, attribute-value table). In this network management tabbing example the multi-tabbing is not a simple layering as in the map example. The combination of multiple tabs presents information that's optimized for the multi-selection and how best to server the needs of the user.
[0024] In the present disclosure, the methods disclosed may be implemented as sets of instructions or software readable by a device. Further, it is understood that the specific order or hierarchy of steps in the methods disclosed are examples of exemplary approaches. Based upon design preferences, it is understood that the specific order or hierarchy of steps in the method can be rearranged while remaining within the disclosed subject matter. The accompanying method claims present elements of the various steps in a sample order, and are not necessarily meant to be limited to the specific order or hierarchy presented.
[0025] It is believed that the present disclosure and many of its attendant advantages will be understood by the foregoing description, and it will be apparent that various changes may be made in the form, construction and arrangement of the components without departing from the disclosed subject matter or without sacrificing all of its material advantages. The form described is merely explanatory, and it is the intention of the following claims to encompass and include such changes. | A method for extending known single-select mutually-exclusive tabs to simultaneously include multiple selection tabs with easy surfaced user controls. These controls enable the user to quickly and easily select and unselect one or more tabs in the tab group. | 10,905 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority from Taiwan patent application TW 103 124 194, filed Jul. 14, 2014, the contents of which are herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a pulley for an alternator, and in particular, to a pulley for an automotive alternator.
[0003] An alternator is a type of generator that can produce an alternating current by converting mechanical energy into electrical energy. An automotive alternator converts mechanical energy of an engine into electrical energy to charge a battery, so as to supply electrical power to other electrical appliances on the automobile, and start a motor to rotate the engine.
[0004] An alternator generally has an annular stator and a rotor received in the annular stator. A wire is wound on the stator, and the rotor rotates rapidly in the stator so that the wire moves relative to a magnetic field generated by the rotor, and an induced electromotive force (voltage) is generated in the wire.
[0005] An automotive alternator is usually utilized by an engine driving a belt. The belt is wound on a pulley, and the pulley is connected to a rotor so as to drive the rotor to rotate. However, in conventional alternator design, when an engine starts, or accelerates or decelerates quickly in an instant, a waveform changes significantly at the moment the generator charges a battery, and it cannot be stabilized. In addition, one side of the belt wound on the pulley is tight, and the other side thereof is slack. The tension of the slack-side belt is low, and therefore a tensioner is disposed thereon to adjust the tension of the belt. However, when a rotation speed at which the engine transmits power changes suddenly, because the pulley of the generator is locked by a nut and the belt is made of a flexible material and cannot reflect the rotation speed immediately, a slip is easily caused between the belt and the pulley. Moreover, the fluctuation of the rotation speed causes the belt to bear not only a repeated stress but also a centrifugal force that is applied on the belt when the pulley rotates. The value of the centrifugal force changes with the rotation speed, and therefore the belt is often affected by adverse factors of an internal micro tension, which pulls the belt, and external large-amplitude shaking.
SUMMARY
[0006] The present invention provides a pulley for an alternator, which includes an outer wheel, provided with an axle hole at the center; a clutch wheel, fixedly disposed in the axle hole of the outer wheel and having a pivot hole; a hollow connecting shaft, having a first end and a second end, where the first end is rotatably disposed in the pivot hole of the clutch wheel, so that the hollow connecting shaft maintains a co-rotational relationship with the outer wheel in a first relative rotation direction by means of the clutch wheel, while in a second relative rotation direction, the hollow connecting shaft is disassociated from the co-rotational relationship with the outer wheel, and presents an idling state; and the second end of the hollow connecting shaft is provided with a first protruding portion; a hollow core shaft, having a first end and a second end, where the hollow core shaft is rotatably received in the outer wheel, and the second end of the hollow core shaft is rotatably arranged at the second end of the hollow connecting shaft; the second end of the hollow core shaft is provided with a second protruding portion, and the second protruding portion corresponds to the first protruding portion; the number of one of the first protruding portion and the second protruding portion is at least one, and the number of the other of the first protruding portion and the second protruding portion is at least two; and an elastic element, disposed between the second end of the hollow connecting shaft and the second end of the hollow core shaft.
[0007] When an external force drives the outer wheel to rotate, the outer wheel rotates relative to the hollow connecting shaft in the first relative rotation direction, and drives, through the clutch wheel, the hollow connecting shaft to rotate synchronously; the second end of the hollow connecting shaft presses the elastic element, and while being pressed, the elastic element pushes the second end of the hollow core shaft, thereby driving the hollow core shaft to rotate; and if a rotation angle of the hollow connecting shaft relative to the hollow core shaft exceeds a predetermined value at this time, the first protruding portion of the hollow connecting shaft contacts the second protruding portion of the hollow core shaft, thereby stopping relative rotation between the hollow connecting shaft and the hollow core shaft, so as to prevent the elastic element from being pressed excessively, and to set the hollow connecting shaft and the hollow core shaft in a synchronous co-rotational relationship. When the external force decreases or stops driving the outer wheel to rotate, the hollow core shaft continues to rotate due to inertia, and stretches the elastic element, and while being stretched, the elastic element pulls the second end of the hollow connecting shaft, thereby driving the hollow connecting shaft to rotate relative to the outer wheel in the second relative rotation direction, so that the hollow connecting shaft is disassociated from the co-rotational relationship with the outer wheel, and idles in the clutch wheel; and if a rotation angle of the hollow connecting shaft relative to the hollow core shaft exceeds a predetermined value at this time, the first protruding portion of the hollow connecting shaft contacts the second protruding portion of the hollow core shaft, thereby stopping relative rotation between the hollow connecting shaft and the hollow core shaft, so as to prevent the elastic element from being stretched excessively, and to set the hollow connecting shaft and the hollow core shaft in a synchronous co-rotational relationship.
[0008] According to another preferred embodiment of the present invention, the hollow core shaft passes through the hollow connecting shaft, and the first end of the hollow core shaft protrudes from the first end of the hollow connecting shaft; a tight-fit component is sleeved over an outer circumferential wall surface of the first end of the hollow core shaft in a tight-fit manner, and the tight-fit component is also tightly fit with an end surface of the first end of the hollow connecting shaft; therefore, the hollow connecting shaft and the hollow core shaft are made to corotate coaxially under a friction between the tight-fit component and the hollow connecting shaft and a friction between the tight-fit component and the hollow core shaft, and when the external force decreases or stops driving the outer wheel to rotate, the hollow core shaft continues to rotate due to inertia, and drives, through the tight-fit component, the hollow connecting shaft to rotate relative to the outer wheel in the second relative rotation direction, so that the hollow connecting shaft is disassociated from the co-rotational relationship with the outer wheel and idles in the clutch wheel.
[0009] According to another preferred embodiment of the present invention, the tight-fit component is a C-shaped retaining ring.
[0010] According to another preferred embodiment of the present invention, a first ball bearing is sleeved over the first end of the hollow core shaft, a second ball bearing is sleeved over the second end of the hollow core shaft, and the first ball bearing and the second ball bearing are disposed between the hollow core shaft and the outer wheel, so that the hollow core shaft is rotatable relative to the outer wheel.
[0011] According to another preferred embodiment of the present invention, three grooves are provided in a concave manner on an inner circumferential wall surface of the outer wheel, and an anaerobic adhesive is coated in the grooves, so that the clutch wheel, the first ball bearing, and the second ball bearing are separately tightly fit in the grooves, and are fixedly glued in the outer wheel by using the anaerobic adhesive.
[0012] According to another preferred embodiment of the present invention, a positioning casing is further sleeved over the first ball bearing, and an axial position of the pulley on the alternator is limited by the positioning casing.
[0013] According to another preferred embodiment of the present invention, an outer circumferential wall surface of the outer wheel is provided with a belt groove, for a belt to be wound on.
[0014] According to another preferred embodiment of the present invention, the belt is connected to a mechanical energy generating source, and the mechanical energy generating source provides an external force to drive the belt, thereby driving the outer wheel to rotate.
[0015] According to another preferred embodiment of the present invention, the mechanical energy generating source is an engine.
[0016] According to another preferred embodiment of the present invention, an inner circumferential wall surface of the hollow core shaft is provided with a threaded surface, the threaded surface is screwed with a joint lever having corresponding threads, and the joint lever is connected to a rotor, so that the hollow core shaft and the rotor corotate synchronously.
[0017] According to another preferred embodiment of the present invention, an inner circumferential wall surface of the outer wheel is provided with a step portion, for the clutch wheel to abut against, thereby limiting an axial displacement of the clutch wheel.
[0018] According to another preferred embodiment of the present invention, one end of the clutch wheel is provided with a positioning member, to limit an axial position of the clutch wheel, and the positioning member is a C-shaped retaining ring.
[0019] According to another preferred embodiment of the present invention, the elastic element is a torque spring, and a wire profile of the torque spring is circular, elliptical, or rectangular.
[0020] According to another preferred embodiment of the present invention, when the wire profile of the torque spring is rectangular, two end surfaces of the torque spring are grinded, so as to enhance axial positioning of the torque spring and control a free length of the torque spring more precisely.
[0021] According to another preferred embodiment of the present invention, two sides of the clutch wheel are each provided with an oil seal element, so as to prevent liquid in the clutch wheel from flowing into the outer wheel.
[0022] According to another preferred embodiment of the present invention, one side of one of the oil seal elements is provided with a positioning member, and the positioning member is sleeved over an inner side wall surface of the outer wheel in a tight-fit manner, to limit axial positions of the oil seal elements.
[0023] According to another preferred embodiment of the present invention, the positioning member is a C-shaped retaining ring.
[0024] According to another preferred embodiment of the present invention, an end, corresponding to the second end of the hollow core shaft, of the outer wheel is arranged with a dust cover, so as to prevent external dust from entering the outer wheel.
[0025] The present invention further provides a pulley for an alternator, which includes an outer wheel, provided with an axle hole at the center; a clutch wheel, fixedly disposed in the axle hole of the outer wheel and having a pivot hole; a hollow connecting shaft, having a first end and a second end, where the first end is rotatably disposed in the pivot hole of the clutch wheel, so that the hollow connecting shaft maintains a co-rotational relationship with the outer wheel in a first relative rotation direction by means of the clutch wheel, while in a second relative rotation direction, the hollow connecting shaft is disassociated from the co-rotational relationship with the outer wheel, and presents an idling state; and the second end of the hollow connecting shaft is provided with a first protruding portion; a hollow core shaft, having a first end and a second end, where the hollow core shaft is rotatably received in the outer wheel, and the hollow core shaft passes through the hollow connecting shaft; the first end of the hollow core shaft protrudes from the first end of the hollow connecting shaft, and the second end of the hollow core shaft is rotatably arranged on the second end of the hollow connecting shaft; the second end of the hollow core shaft is provided with a second protruding portion, and the second protruding portion corresponds to the first protruding portion; the number of one of the first protruding portion and the second protruding portion is at least one, and the number of the other of the first protruding portion and the second protruding portion is at least two; an elastic element, disposed between the second end of the hollow connecting shaft and the second end of the hollow core shaft; and a tight-fit component, sleeved over an outer circumferential wall surface of the first end of the hollow core shaft in a tight-fit manner and tightly fit with an end surface of the first end of the hollow connecting shaft, so that the hollow connecting shaft and the hollow core shaft corotate coaxially under a friction between the tight-fit component and the hollow connecting shaft and a friction between the tight-fit component and the hollow core shaft.
[0026] When an external force drives the outer wheel to rotate, the outer wheel rotates relative to the hollow connecting shaft in the first relative rotation direction, and drives, through the clutch wheel, the hollow connecting shaft to rotate synchronously, and the hollow connecting shaft drives, through the tight-fit component, the hollow core shaft to rotate; if the friction provided by the tight-fit component is insufficient to drive the hollow core shaft to rotate at this time, the second end of the hollow connecting shaft presses the elastic element, and while being pressed, the elastic element pushes the second end of the hollow core shaft, thereby driving the hollow core shaft to rotate; and if a rotation angle of the hollow connecting shaft relative to the hollow core shaft exceeds a predetermined value at this time, the first protruding portion of the hollow connecting shaft contacts the second protruding portion of the hollow core shaft, thereby stopping relative rotation between the hollow connecting shaft and the hollow core shaft, so as to prevent the elastic element from being pressed excessively, and to set the hollow connecting shaft and the hollow core shaft in a synchronous co-rotational relationship. When the external force decreases or stops driving the outer wheel to rotate, the hollow core shaft continues to rotate due to inertia, and drives, through the tight-fit component, the hollow connecting shaft to rotate relative to the outer wheel in the second relative rotation direction; and if the friction provided by the tight-fit component is insufficient to drive the hollow connecting shaft to rotate at this time, the hollow core shaft rotates relative to the hollow connecting shaft until the first protruding portion of the hollow connecting shaft contacts the second protruding portion of the hollow core shaft, thereby stopping relative rotation between the hollow connecting shaft and the hollow core shaft, and setting the hollow connecting shaft and the hollow core shaft in a synchronous co-rotational relationship.
[0027] According to another preferred embodiment of the present invention, when the external force decreases or stops driving the outer wheel to rotate, the hollow core shaft continues to rotate due to inertia, and drives, through the tight-fit component, the hollow connecting shaft to rotate relative to the outer wheel in the second relative rotation direction; if the friction provided by the tight-fit component is insufficient to drive the hollow connecting shaft to rotate at this time, the hollow core shaft stretches the elastic element, and while being stretched, the elastic element pulls the second end of the hollow connecting shaft, thereby driving the hollow connecting shaft to rotate relative to the outer wheel in the second relative rotation direction, so that the hollow connecting shaft is disassociated from the co-rotational relationship with the outer wheel; and if a rotation angle of the hollow connecting shaft relative to the hollow core shaft exceeds a predetermined value, the protruding portion of the hollow connecting shaft contacts the protruding portion of the hollow core shaft, thereby stopping relative rotation between the hollow connecting shaft and the hollow core shaft, so as to prevent the elastic element from being stretched excessively, and to set the hollow connecting shaft and the hollow core shaft in a synchronous co-rotational relationship.
[0028] According to another preferred embodiment of the present invention, the tight-fit component is a C-shaped retaining ring.
[0029] According to another preferred embodiment of the present invention, a first ball bearing is sleeved over the first end of the hollow core shaft, a second ball bearing is sleeved over the second end of the hollow core shaft, and the first ball bearing and the second ball bearing are disposed between the hollow core shaft and the outer wheel, so that the hollow core shaft is rotatable relative to the outer wheel.
[0030] According to another preferred embodiment of the present invention, three grooves are provided in a concave manner on an inner circumferential wall surface of the outer wheel, and an anaerobic adhesive is coated in the grooves, so that the clutch wheel, the first ball bearing, and the second ball bearing are separately tightly fit in the grooves, and are fixedly glued in the outer wheel by using the anaerobic adhesive.
[0031] According to another preferred embodiment of the present invention, a positioning casing is further sleeved over the first ball bearing, and an axial position of the pulley on the alternator is limited by the positioning casing.
[0032] According to another preferred embodiment of the present invention, an outer circumferential wall surface of the outer wheel is provided with a belt groove, for a belt to be wound on.
[0033] According to another preferred embodiment of the present invention, the belt is connected to a mechanical energy generating source, and the mechanical energy generating source provides an external force to drive the belt, thereby driving the outer wheel to rotate.
[0034] According to another preferred embodiment of the present invention, the mechanical energy generating source is an engine.
[0035] According to another preferred embodiment of the present invention, an inner circumferential wall surface of the hollow core shaft is provided with a threaded surface, the threaded surface is screwed with a joint lever having corresponding threads, and the joint lever is connected to a rotor, so that the hollow core shaft and the rotor corotate synchronously.
[0036] According to another preferred embodiment of the present invention, an inner circumferential wall surface of the outer wheel is provided with a step portion, for the clutch wheel to abut against, thereby limiting an axial displacement of the clutch wheel.
[0037] According to another preferred embodiment of the present invention, one end of the clutch wheel is provided with a positioning member, to limit an axial position of the clutch wheel, and the positioning member is a C-shaped retaining ring.
[0038] According to another preferred embodiment of the present invention, the elastic element is a torque spring, and a wire profile of the torque spring is circular, elliptical, or rectangular.
[0039] According to another preferred embodiment of the present invention, when the wire profile of the torque spring is rectangular, two end surfaces of the torque spring are grinded, so as to enhance axial positioning of the torque spring and control a free length of the torque spring more precisely.
[0040] According to another preferred embodiment of the present invention, two sides of the clutch wheel are each provided with an oil seal element, so as to prevent liquid in the clutch wheel from flowing into the outer wheel.
[0041] According to another preferred embodiment of the present invention, one side of one of the oil seal elements is provided with a positioning member, and the positioning member is sleeved over an inner side wall surface of the outer wheel in a tight-fit manner, to limit axial positions of the oil seal elements.
[0042] According to another preferred embodiment of the present invention, the positioning member is a C-shaped retaining ring.
[0043] According to another preferred embodiment of the present invention, an end, corresponding to the second end of the hollow core shaft, of the outer wheel is arranged with a dust cover, so as to prevent external dust from entering the outer wheel.
[0044] The present invention further provides an alternator having the pulley according to the present invention.
[0045] According to another preferred embodiment of the present invention, the alternator is used on a vehicle.
[0046] For better understanding of the detailed description of the present invention, the features and technical advantages of the present invention are described generally above. The following describes the additional features and advantages of the present invention. Persons skilled in the art should be aware that the disclosed concept and specific implementation manner can be easily used as a basis for modifying or designing other structures for implementing objectives the same as the present invention. Persons skilled in the art should also be aware that such equivalent structures do not depart from the spirit and scope of the present invention which are claimed in the patent application scope.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] For a more thorough understanding of the present invention and advantages of the present invention, the following descriptions are provided with reference to the accompanying drawings, where:
[0048] FIG. 1 is a three-dimensional exploded view of a pulley for an alternator according to the present invention;
[0049] FIG. 2 is a sectional assembled view of a pulley for an alternator according to the present invention;
[0050] FIG. 3 is a schematic structural view of a hollow connecting shaft according to the present invention;
[0051] FIG. 4 is a schematic structural view of a hollow core shaft according to the present invention; and
[0052] FIG. 5 is a schematic view of a rotor of an alternator according to the present invention.
MEANING OF REFERENCE NUMERALS
[0000]
10 Pulley
20 Joint lever
30 Rotor
110 Outer wheel
111 Axle hole
112 Belt groove
113 Step portion
120 Clutch wheel
121 Pivot hole
122 Housing
123 Rolling member
124 Elastic member
125 Cap
130 Hollow connecting shaft
131 First end of the hollow connecting shaft
132 Second end of the hollow connecting shaft
133 First protruding portion
134 Stop wall of the hollow connecting shaft
140 Hollow core shaft
141 First end of the hollow core shaft
142 Second end of the hollow core shaft
143 First ball bearing
144 Second ball bearing
145 Protruding ring of the hollow core shaft
146 Second protruding portion
147 Stop wall of the hollow core shaft
148 Threaded surface
150 Elastic element
160 Tight-fit component
161 Positioning gasket
162 C-shaped retaining ring
170 Positioning casing
171 Protruding ring of the positioning casing
181 Oil seal element
182 Oil seal element
183 Positioning member
184 Dust cover
185 Positioning member
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0091] The following embodiments describe the present invention in further detail. The embodiments are merely used to describe the present invention and illustrate the advantages of specific embodiments of the present invention, but it does not mean that the present invention is limited to such implementations.
[0092] FIG. 1 and FIG. 2 are respectively a three-dimensional exploded view and a sectional assembled view of a pulley for an alternator according to the present invention. As shown in FIG. 1 and FIG. 2 , a pulley 10 for an alternator according to the present invention mainly includes an outer wheel 110 , a clutch wheel 120 , a hollow connecting shaft 130 , a hollow core shaft 140 , an elastic element 150 , and a tight-fit component 160 . The outer wheel 110 is a wheel-shaped member provided with an axle hole 111 at the center, and is provided with a belt groove 112 on an outer circumferential wall surface thereof and a step portion 113 on an inner circumferential wall surface thereof. The clutch wheel 120 is annular, provided with a pivot hole 121 at the center, and fixedly disposed in the axle hole 111 of the outer wheel 110 . For example, a groove may be provided in a concave manner on the inner circumferential wall surface of the outer wheel 110 , and an anaerobic adhesive is coated in the groove so that the clutch wheel 120 can be fixedly connected to an inner circumferential wall surface of the axle hole 111 of the outer wheel 110 by means of tight fit and adhesion of the anaerobic adhesive. One end of the clutch wheel 120 abuts against the step portion 113 of the outer wheel 110 to limit an axial position of the clutch wheel 120 and to ensure that an end surface of the clutch wheel 120 is perpendicular to the hollow connecting shaft 130 and the hollow core shaft 140 , prevent axial displacement of the clutch wheel 120 during high-speed rotation, and moreover, provide an axial positioning reference during assembly of components in the outer wheel 110 , which facilitates positioning during the assembly.
[0093] The hollow connecting shaft 130 has a first end 131 and a second end 132 . The first end 131 is rotatably disposed in the clutch wheel 120 so that the hollow connecting shaft 130 can maintain a co-rotational relationship with the outer wheel 110 in a first relative rotation direction by means of the clutch wheel 120 (for example, the hollow connecting shaft 130 rotates anticlockwise relative to the outer wheel 110 ), and it is disassociated from the co-rotational relationship with the outer wheel 110 in a second relative rotation direction to enter an idling state (for example, the hollow connecting shaft 130 rotates clockwise relative to the outer wheel 110 ), and at this time, the hollow connecting shaft 130 rotates independently of the outer wheel 110 . The hollow connecting shaft 130 is provided with a first protruding portion 133 on the second end 132 , as shown in FIG. 3 .
[0094] In a preferred embodiment of the present invention, the clutch wheel 120 has a housing 122 , a plurality of rolling members 123 , a plurality of elastic members 124 , and two caps 125 . The clutch wheel 120 is provided with a positioning member 185 on an end opposite to the end abutting against the step portion 113 to limit the axial position of the clutch wheel 120 and prevent the caps 125 of the clutch wheel 120 from falling off. The positioning member may be a C-shaped retaining ring. For the detailed structure and operating principle of the clutch wheel 120 , reference may be made to Taiwan Patent Application No. 098129945 filed by the applicant on Sep. 4, 2009. However, the clutch wheel of the present invention is not limited thereto, and any speed-difference clutch apparatus capable of implementing the functions of the clutch wheel 120 described in the present invention may be designed as the clutch wheel 120 of the present invention. Moreover, in the present invention, two ends of the clutch wheel 120 are each provided with an oil seal element 181 / 182 so as to prevent a liquid (for example, a lubricating oil) in the clutch wheel 120 from permeating and polluting the interior of the pulley 10 . Furthermore, a positioning member 183 may be sleeved over one side of the oil seal element 182 . The positioning member 183 may be a C-shaped retaining ring, and may be sleeved over an inner side wall surface of the outer wheel 110 in a tight-fit manner, to limit axial positions of the oil seal elements 181 and 182 and the clutch wheel 120 .
[0095] The hollow core shaft 140 is disposed in the outer wheel 110 and has a first end 141 and a second end 142 . A first ball bearing 143 is sleeved over the first end 141 , and a second ball bearing 144 is sleeved over the second end 142 . The first ball bearing 143 and the second ball bearing 144 are both fixedly connected to the inner circumferential wall surface of the outer wheel 110 (for example, the outer wheel 110 may be provided with two grooves on the inner circumferential wall surface in a concave manner, and an anaerobic adhesive is coated in the grooves so that the first ball bearing 143 and the second ball bearing 144 can be fixedly connected to the inner circumferential wall surface of the axle hole 111 of the outer wheel 110 by means of tight fit and adhesion of the anaerobic adhesive) so that the hollow core shaft 140 is rotatable relative to the outer wheel 110 . In addition, the hollow core shaft 140 passes through the hollow connecting shaft 130 , and the first end 141 of the hollow core shaft 140 protrudes from the first end 131 of the hollow connecting shaft 130 . A protruding ring 145 is annularly arranged at the second end 142 of the hollow core shaft 140 . The protruding ring 145 is rotatably arranged on the second end 132 of the hollow connecting shaft 130 . A second protruding portion 146 is provided in a protruding manner in a direction towards the hollow connecting shaft 130 , and the second protruding portion 146 corresponds to the first protruding portion 133 so that after the hollow connecting shaft 130 and the hollow core shaft 140 rotate by a particular degree relative to each other, the first protruding portion 133 of the hollow connecting shaft 130 contacts the second protruding portion 146 of the hollow core shaft 140 , thereby stopping relative rotation between the hollow connecting shaft 130 and the hollow core shaft 140 . For example, when the hollow connecting shaft 130 is provided with two first protruding portions 133 at the second end 132 , and when the hollow core shaft 140 is provided with three second protruding portions 146 at the second end 142 , the hollow core shaft 140 can only rotate clockwise or anticlockwise by 120 degrees relative to the hollow connecting shaft 130 after being sleeved over the hollow connecting shaft 130 because relative rotation between the hollow connecting shaft 130 and the hollow core shaft 140 is stopped when the first protruding portions 133 contact the second protruding portions 146 .
[0096] The elastic element 150 is disposed between the second end 132 of the hollow connecting shaft 130 and the second end 142 of the hollow core shaft 140 . In a preferred embodiment of the present invention, the elastic element is a torque spring, and a wire profile of the torque spring may be circular, elliptical, or rectangular. When the wire profile of the torque spring is rectangular, two end surfaces of the torque spring may be grinded so as to enhance an axial positioning capability of the torque spring and control a free length of the spring more precisely. The hollow connecting shaft 130 is provided with a stop wall 134 in a concave manner on an inner circumferential wall surface of the second end 132 (as shown in FIG. 3 ) so that one end of the elastic element 150 can abut against the stop wall 134 , and the elastic element 150 may also be fixedly connected to the stop wall 134 . In addition, The hollow core shaft 140 is also provided with a stop wall 147 on an inner side of the protruding ring 145 of the second end 142 (as shown in FIG. 4 ) so that the other end of the elastic element 150 can abut against the stop wall 147 , and the elastic element 150 may also be fixedly connected to the stop wall 147 . When the two ends of the elastic element 150 are fixedly connected to the stop wall 134 of the hollow connecting shaft 130 and the stop wall 147 of the hollow core shaft 140 , relative rotation between the hollow connecting shaft 130 and the hollow core shaft 140 presses or stretches the elastic element 150 ; when the two ends of the elastic element 150 merely abut against but are not fixedly connected to the stop wall 134 of the hollow connecting shaft 130 or the stop wall 147 of the hollow core shaft 140 , relative rotation between the hollow connecting shaft 130 and the hollow core shaft 140 only presses the elastic element 150 .
[0097] The tight-fit component 160 is a C-shaped retaining ring; the C-shaped retaining ring is sleeved over the outer circumferential wall surface of the first end 141 of the hollow core shaft 140 in a tight-fit manner, and is tightly fit with a tail end surface of the first end 131 of the hollow connecting shaft 130 . Therefore, under a friction between the tight-fit component 160 and the end surface of the first end 131 of the hollow connecting shaft 130 and a friction between the tight-fit component 160 and the outer circumferential wall surface of the first end 141 of the hollow core shaft 140 , the hollow connecting shaft 130 and the hollow core shaft 140 drive each other and corotate coaxially, as shown in FIG. 3 .
[0098] A positioning casing 170 is further sleeved over the first ball bearing 143 , and the positioning casing 170 is a hollow annular pipe provided with a protruding ring 171 at one end; therefore, the protruding ring 171 penetrates the first ball bearing 143 and provides an abutting and cushioning function when the pulley 10 is installed on an alternator, and an axial position of the pulley 10 on the alternator is limited by the positioning casing 170 .
[0099] The hollow core shaft 140 is provided with a threaded surface 148 on an inner circumferential wall surface thereof, the threaded surface 148 may be screwed with a joint lever 20 having corresponding threads, and the joint lever 20 is connected to a rotor 30 of the alternator so that the hollow core shaft 140 and the rotor 30 corotate synchronously (as shown in FIG. 5 ). In addition, an end, corresponding to the second end 142 of the hollow core shaft 140 , of the outer wheel 110 is arranged with a dust cover 184 so as to prevent external dust from entering the outer wheel 110 .
[0100] With the structure described above, when a mechanical energy generating source provides an external force to drive the outer wheel 110 to rotate, the outer wheel 110 rotates relative to the hollow connecting shaft 130 in the first relative rotation direction and drives, through the clutch wheel 120 , the hollow connecting shaft 130 to rotate synchronously, and with the friction provided by the tight-fit component 160 , the hollow connecting shaft 130 drives the hollow core shaft 140 to rotate. At this time, if the friction provided by the tight-fit component 160 is insufficient to drive the hollow core shaft 140 to rotate, the hollow connecting shaft 130 rotates relative to the hollow core shaft 140 , which causes the stop wall 134 at the second end 132 of the hollow connecting shaft 130 to press the elastic element 150 , and while being pressed, the elastic element 150 pushes the stop wall 147 at the second end 142 of the hollow core shaft 140 , thereby driving the hollow core shaft 140 to rotate. At this time, if a relative rotation angle between the hollow connecting shaft 130 and the hollow core shaft 140 exceeds a predetermined value (for example, 120 degrees), the first protruding portion 133 of the hollow connecting shaft 130 contacts the second protruding portion 146 of the hollow core shaft 140 , thereby stopping relative rotation between the hollow connecting shaft 130 and the hollow core shaft 140 so as to avoid pressing the elastic element 150 excessively and damaging the structure thereof, and to set the hollow connecting shaft 130 and the hollow core shaft 140 in a synchronous co-rotational relationship; the hollow core shaft 140 also drives the rotor 30 to rotate so that the alternator generates an induced current.
[0101] In addition, if the outer wheel 110 is originally in a rotation state, when the mechanical energy generating source provides an external force to accelerate the rotation of the outer wheel 110 , an operating principle of the pulley 10 of the present invention is substantially the same as the aforementioned operating principle in the case of starting the outer wheel 110 to rotate, and therefore it is not repeated herein.
[0102] On the contrary, when the external force stops driving the outer wheel 110 to rotate, the hollow core shaft 140 continues to rotate due to inertia of the rotor 30 . At this time, the hollow core shaft 140 drives, by using the friction provided by the tight-fit component 160 , the hollow connecting shaft 130 to rotate relative to the outer wheel 110 in the second relative rotation direction so that the hollow connecting shaft 130 is disassociated from the co-rotational relationship with the outer wheel 110 . At this time, if the friction provided by the tight-fit component 160 is insufficient to drive the hollow connecting shaft 130 to rotate, the hollow core shaft 140 rotates relative to the hollow connecting shaft 130 ; if the elastic element 150 merely abuts against but is not fixedly connected to the hollow connecting shaft 130 and the hollow core shaft 140 , the hollow core shaft 140 keeps rotating relative to the hollow connecting shaft 130 until the second protruding portion 146 of the hollow core shaft 140 contacts the first protruding portion 133 of the hollow connecting shaft 130 , thereby stopping relative rotation between the hollow connecting shaft 130 and the hollow core shaft 140 and setting the hollow connecting shaft 130 and the hollow core shaft 140 in a synchronous co-rotational relationship so that the hollow connecting shaft 130 and the hollow core shaft 140 rotate relative to the outer wheel 110 in the second relative rotation direction.
[0103] If the elastic element 150 is fixedly connected to the hollow connecting shaft 130 and the hollow core shaft 140 , when the friction provided by the tight-fit component 160 is insufficient to drive the hollow connecting shaft 130 to rotate, the hollow core shaft 140 rotates relative to the hollow connecting shaft 130 and stretches the elastic element 150 , and while being stretched, the elastic element 150 pulls the second end 132 of the hollow connecting shaft 130 , thereby driving the hollow connecting shaft 130 to rotate relative to the outer wheel 110 in the second relative rotation direction so that the hollow connecting shaft 130 is disassociated from the co-rotational relationship with the outer wheel 110 . At this time, if rotation of the hollow connecting shaft 130 relative to the hollow core shaft 140 exceeds a predetermined value (for example, 120 degrees), the first protruding portion 133 of the hollow connecting shaft 130 contacts the second protruding portion 146 of the hollow core shaft 140 , thereby stopping relative rotation between the hollow connecting shaft 130 and the hollow core shaft 140 so as to avoid stretching the elastic element 150 excessively and damaging the structure thereof, and to set the hollow connecting shaft 130 and the hollow core shaft 140 in a synchronous co-rotational relationship so that the hollow connecting shaft 130 and the hollow core shaft 140 rotate relative to the outer wheel 110 in the second relative rotation direction.
[0104] In addition, if the external force driving the outer wheel 110 decreases, the operating principle of the pulley 10 of the present invention is substantially the same as the aforementioned operating principle in the case in which the outer wheel 110 stops rotating, and therefore it is not repeated herein.
[0105] In the pulley 10 of the present invention, a belt (not shown in the figure) may be wound on the belt groove 112 of the outer wheel 110 so that the mechanical energy generating source can provide an external force to drive the belt, thereby driving the outer wheel 110 to rotate. In addition, the pulley 10 of the present invention is applicable to an alternator system, such as a power generation system and an alternator system of a vehicle. The pulley of the present invention is especially suitable to be used as a stator structure of an automotive alternator. When the pulley of the present invention is applied to an automotive alternator, the mechanical energy generating source is an automobile engine.
[0106] In a preferred embodiment of the present invention, the tight-fit component 160 of the pulley 10 of the present invention may be omitted, and two ends of the elastic element 150 are fixedly connected to the stop wall 147 at the second end 142 of the hollow core shaft 140 and the stop wall 134 at the second end 132 of the hollow connecting shaft 130 . In this manner, when an external force drives the outer wheel 110 to rotate, the outer wheel 110 rotates relative to the hollow connecting shaft 130 in the first relative rotation direction and drives, through the clutch wheel 120 , the hollow connecting shaft 130 to rotate synchronously; the second end 132 of the hollow connecting shaft 130 presses the elastic element 150 , and while being pressed, the elastic element 150 pushes the stop wall 147 at the second end 142 of the hollow core shaft 140 , thereby driving the hollow core shaft 140 to rotate. At this time, if a rotation angle of the hollow connecting shaft 130 relative to the hollow core shaft 140 exceeds a predetermined value, the first protruding portion 133 of the hollow connecting shaft 130 contacts the second protruding portion 146 of the hollow core shaft 140 , thereby stopping relative rotation between the hollow connecting shaft 130 and the hollow core shaft 140 so as to prevent the elastic element 150 from being pressed excessively, setting the hollow connecting shaft 130 and the hollow core shaft 140 in a synchronous co-rotational relationship, and drive the rotor 30 to rotate.
[0107] On the contrary, when the external force decreases or stops driving the outer wheel 110 to rotate, the hollow core shaft 140 continues to rotate due to inertia of the rotor 30 and stretches the elastic element 150 , and while being stretched, the elastic element 150 pulls the second end 132 of the hollow connecting shaft 130 , thereby driving the hollow connecting shaft 130 to rotate relative to the outer wheel 110 in the second relative rotation direction so that the hollow connecting shaft 130 is disassociated from the co-rotational relationship with the outer wheel 110 and idles in the clutch wheel 120 . At this time, if a rotation angle of the hollow connecting shaft 130 relative to the hollow core shaft 140 exceeds a predetermined value, the first protruding portion 133 of the hollow connecting shaft 130 contacts the second protruding portion 146 of the hollow core shaft 140 , thereby stopping relative rotation between the hollow connecting shaft 130 and the hollow core shaft 140 so as to prevent the elastic element 150 from being stretched excessively, and to set the hollow connecting shaft 130 and the hollow core shaft 140 in a synchronous co-rotational relationship, in which the hollow connecting shaft 130 and the hollow core shaft 140 idle in the outer wheel 110 . In addition, in a preferred embodiment of the present invention, in the pulley 10 of the present invention, the first protruding portion 133 and the second protruding portion 146 may not be disposed, the protruding ring 145 at the second end 142 of the hollow core shaft 140 is directly sleeved over the second end 132 of the hollow connecting shaft 130 , and two ends of the elastic element 150 are fixedly connected to the stop wall 147 at the second end 142 of the hollow core shaft 140 and the stop wall 134 at the second end 132 of the hollow connecting shaft 130 . Therefore, when an external force drives the outer wheel 110 to rotate, the outer wheel 110 rotates relative to the hollow connecting shaft 130 in the first relative rotation direction and drives, through the clutch wheel 120 , the hollow connecting shaft 130 to rotate synchronously, and the hollow connecting shaft 130 drives, through the tight-fit component 160 , the hollow core shaft 140 to rotate. At this time, if the friction provided by the tight-fit component 160 is insufficient to drive the hollow core shaft 140 to rotate, the stop wall 134 at the second end 132 of the hollow connecting shaft 130 presses the elastic element 150 , and while being pressed, the elastic element 150 pushes the stop wall 147 at the second end 142 of the hollow core shaft 140 , thereby driving the hollow core shaft 140 to rotate, so as to drive the rotor 30 of the alternator to rotate.
[0108] On the contrary, when the external force decreases or stops driving the outer wheel 110 to rotate, the hollow core shaft 140 continues to rotate due to inertia of the rotor 30 and drives, through the tight-fit component 160 , the hollow connecting shaft 130 to rotate relative to the outer wheel 110 in the second relative rotation direction. At this time, if the friction provided by the tight-fit component 160 is insufficient to drive the hollow connecting shaft 130 to rotate, the hollow core shaft 140 stretches the elastic element 150 , and while being stretched, the elastic element 150 pulls the second end 132 of the hollow connecting shaft 130 , thereby driving the hollow connecting shaft 130 to rotate relative to the outer wheel 110 in the second relative rotation direction so that the hollow connecting shaft 130 is disassociated from the co-rotational relationship with the outer wheel 110 and idles in the clutch wheel 120 .
[0109] Further, in a preferred embodiment of the present invention, in the pulley 10 of the present invention, the tight-fit component 160 , the first protruding portion 133 , and the second protruding portion 146 may not be disposed; the protruding ring 145 at the second end 142 of the hollow core shaft 140 is directly sleeved over the second end 132 of the hollow connecting shaft 130 , and two ends of the elastic element 150 are fixedly connected to the stop wall 147 at the second end 142 of the hollow core shaft 140 and the stop wall 134 at the second end 132 of the hollow connecting shaft 130 . In this manner, when an external force drives the outer wheel 110 to rotate, the outer wheel 110 rotates relative to the hollow connecting shaft 130 in the first relative rotation direction and drives, through the clutch wheel 120 , the hollow connecting shaft 130 to rotate synchronously; the stop wall 134 at the second end 132 of the hollow connecting shaft 130 presses the elastic element 150 , and while being pressed, the elastic element 150 pushes the stop wall 147 at the second end 142 of the hollow core shaft 140 , thereby driving the hollow core shaft 140 to rotate.
[0110] On the contrary, when the external force decreases or stops driving the outer wheel 110 to rotate, the hollow core shaft 140 continues to rotate due to inertia of the rotor 30 and stretches the elastic element 150 , and while being stretched, the elastic element 150 pulls the second end 132 of the hollow connecting shaft 130 , thereby driving the hollow connecting shaft 130 to rotate relative to the outer wheel 110 in the second relative rotation direction so that the hollow connecting shaft 130 is disassociated from the co-rotational relationship with the outer wheel 110 and idles in the clutch wheel 120 .
[0111] Although the present invention and advantages thereof are described in detail above, it should be understood that variations, alternative solutions, and modifications can be made herein without departing from the spirit and scope of the present invention which are defined in the appended patent application scope. Moreover, the scope of the present invention is not limited to the specific implementations of the process, machine, product, material composition, means, method, and steps described in the specification. For example, persons skilled in the art can easily learn from the disclosure of the present invention that existing or to-be-developed processes, machines, products, material compositions, means, methods and steps that substantially implement the same function or substantially achieve the same result as the corresponding implementation manner described herein may be used. Correspondingly, the appended patent application scope is intended to cover such processes, machines, products, material compositions, means, methods or steps. | The present invention relates to a pulley for an alternator, and in particular, to a pulley applicable to an automotive alternator. The pulley effectively mitigates the problem that a belt and a tension pulley of an alternator vibrate because a rotation speed of a vehicle engine changes, thereby improving the overall operating efficiency of the alternator and the service life of the working belt and the tension pulley. | 51,487 |
CLAIM OF PRIORITY
The present application claims priority from Japanese Patent Application No. 10-364079, filed Dec. 22, 1998 and is a continuation application of application Ser. No. 13/242,632, filed Sep. 23, 2011, which is a continuation of application Ser. No. 13/016,104, filed Jan. 28, 2011, now U.S. Pat. No. 8,051,244, which is a continuation of application Ser. No. 12/561,462 filed Sep. 17, 2009, now U.S. Pat. No. 7,937,527, which is a continuation of application Ser. No. 10/898,259, filed Jul. 26, 2004, now U.S. Pat. No. 7,805,564; which is a divisional of application Ser. No. 10/769,922 filed Feb. 3, 2004, now U.S. Pat. No. 6,910,102; which is a continuation of application Ser. No. 10/405,645, filed Apr. 3, 2003, now U.S. Pat. No. 6,851,029; which is a continuation of application Ser. No. 10/095,581, filed Mar. 13, 2002, now U.S. Pat. No. 6,701,411; which is a continuation of application Ser. No. 09/468,327, filed Dec. 21, 1999 now U.S. Pat. No. 6,542,961, the entire contents of which are incorporated herein by reference. This application is related to U.S. Ser. No. 10/095,578, filed Mar. 13, 2002.
BACKGROUND OF THE INVENTION
This invention relates to a disk control system for controlling a plurality of disk devices and relates in particular to a method for improving the high speed operation of the disk control system, achieving a lower cost and improving the cost performance.
A diskarray system for controlling a plurality of disk devices is utilized as a storage system in computers. A diskarray system is for instance disclosed in “A Case for Redundant Arrays of Inexpensive Disks (RAID)”; In Proc. ACM SIGMOD, June 1988 (Issued by Cal. State Univ. Berkeley). This diskarray operates a plurality of disk systems in parallel and is a technique that achieves high speed operation compared to storage systems utilizing disks as single devices.
A method using the fabric of a fiber channel is a technique for mutually connecting a plurality of hosts with a plurality of diskarray systems. A computer system using this technique is disclosed for instance in “Serial SCSI Finally Arrives on the Market” of Nikkei Electronics, P. 79, Jul. 3, 1995 (No. 639) as shown in FIG. 3 . In the computer system disclosed here, a plurality of host computers (hereafter simply called hosts) and a plurality of diskarray systems are respectively connected to a fabric device by way of fiber channels. The fabric device is a switch for the fiber channels and performs transfer path connections between the desired devices. The fabric device is transparent to (or passes) “frame” transfers which are packets on the fiber channel. The host and diskarray system communicate between two points without recognizing the fabric device.
SUMMARY OF THE INVENTION
In diskarray systems of the conventional art, when the number of disk devices were increased in order to increase the storage capacity and achieving a controller having high performance matching the number of disk units was attempted, the internal controller buses were found to have only limited performance and likewise, the processor performing transfer control was also found to have only limited performance. In order to deal with these problems, the internal buses were expanded and the number of processors was increased. However, attempting to solve the problem in this manner made the controller structure more complex due to the control required for a greater number of buses and caused increased overhead and complicated software control due to non-exclusive control of data shared between processors, etc. The rise in cost consequently became extremely high and performance reached its limits so that cost performance was unsatisfactory. Though the cost for this kind could be justified in terms of performance in a large scale system, in systems not on such a large scale the cost did not match performance, expandability was limited and the development period and development costs increased.
The overall system storage capacity and performance can be increased by connecting a plurality of diskarray systems in parallel with a fabric device. However, in this method, there is absolutely no connection between the diskarray systems, and access concentrated on a particular diskarray system cannot be distributed among the other devices so that high performance cannot be achieved in actual operation. Also, the capacity of a logical disk device (hereafter logic unit) as seen from the host is limited to the capacity of one diskarray system so that a high capacity logic unit cannot be achieved.
In an attempt to improve diskarray system reliability, a diskarray system can be comprised of a mirror structure where, in two diskarray systems, the host unit has a mirroring function. However, this method requires overhead due to control required of the mirroring by the host and also has the problem that performance is limited. This method also increases the load that the system administrator must supervise since many diskarray systems are present inside the system. The maintenance costs thus increase since a large number of maintenance personnel must be hired and maintenance fees must be paid for each unit. The plurality of diskarray systems and fabric devices are further all autonomous devices so that the settings must be made by different methods according to the respective device, creating the problem that operating costs increase along with a large increase in operating time and system administrator training time, etc.
In order to resolve these problems with the related art, this invention has the object of providing a disk storage system capable of being structured according to the scale and requirements of the computer system, and a disk storage system that responds easily to needs for high reliability and future expansion.
The disk storage system of this invention contains a storage device having a record medium for holding the data, a plurality of storage sub-systems having a controller for controlling the storage device, a first interface node coupled to a computer using the data stored in the plurality of storage sub-systems, a plurality of second interface nodes connected to any or one of the storage sub-systems, a switch connecting between a first interface node and a plurality of second interface nodes to perform frame transfer between a first interface node and a plurality of second interface nodes based on node address information added to the frame.
The first interface node preferably has a configuration table to store structural information for the memory storage system and a processing unit to analyze the applicable frame in response to the frame sent from the computer, converts information relating to the transfer destination of that frame based on structural information held in the configuration table, and transfers that frame to the switch. Further, when transmitting a frame, the first interface node adds the node address information about the node that must receive the frame, to that frame. A second interface node then removes the node address information from the frame that was received, recreates the frame and transfers that frame to the desired storage sub-system.
In the embodiment of this invention, the disk storage system has a managing processor connecting to the switch. The managing processor sets the structural information in the configuration table of each node according to the operator's instructions. Information for limiting access from the computer is contained in this structural information.
In another embodiment of this invention, the first interface node replies to the command frame sent from the computer instructing the writing of data, makes copies of that command frame and the following data frames, adds different nodes address information to each frame so the received frame and the copied command frames will be sent to the different respective nodes and sends these frames to the switch.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing the structure of the computer system of the first embodiment of this invention.
FIG. 2 is block diagram of the diskarray subset of the first embodiment.
FIG. 3 is block diagram of diskarray switch of the first embodiment.
FIG. 4 is a block diagram of the crossbar switch of the diskarray switch of the first embodiment.
FIG. 5 is block diagram of the host I/F node for the diskarray switch of the first embodiment.
FIG. 6A is sample diskarray system configuration table.
FIG. 6B is sample diskarray system configuration table.
FIG. 7 is a block diagram of the frame of the fiber channel.
FIG. 8 is a block diagram of the frame header of the fiber channel.
FIG. 9 is a block diagram of the frame payload of the fiber channel.
FIG. 10 is a model view showing the sequence of frames sent by way of the fiber channel during read operation from the host.
FIG. 11 is a model view showing the interactive relationship of the host-LU, the LU for each diskarray subset, as well as each diskarray unit.
FIG. 12 is a block diagram of the S packet.
FIG. 13A through 13C are flowcharts of the processing in the host I/F node during write processing.
FIG. 14 is a block diagram showing a plurality of diskarray switches in a cluster-connected diskarray system.
FIG. 15 is a block diagram of the computer system of the second embodiment of this invention.
FIG. 16 is a block diagram of the diskarray switch IC of the fourth embodiment of this invention.
FIG. 17 is a block diagram of the computer system of the fifth embodiment of this invention.
FIG. 18 is a screen configuration view showing a typical display of the logic connection structure.
FIG. 19 is a model diagram showing the frame sequence in the sixth embodiment of this invention.
FIGS. 20A through 20D are flowcharts showing the processing on the host I/F node during the mirroring write processing in the sixth embodiment of this invention.
FIG. 21 is an address spatial diagram of the diskarray system for the seventh embodiment of this invention.
FIG. 22 is a flowchart showing the processing in the host I/F node of the seventh embodiment of this invention.
FIG. 23 is a block diagram of the disaster recovery system of the eight embodiment of this invention.
FIG. 24 is a descriptive view of the alternative path setup.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
(First Embodiment)
FIG. 1 is a block diagram showing the structure of the computer system of the first embodiment of this invention. In the figure, reference numeral 1 denotes a diskarray system, and 30 is the (host) computer connected to the diskarray system. The diskarray system 1 contains a diskarray subset 10 , a diskarray switch 20 and a diskarray system configuration manager 70 for handling the configuration of the overall diskarray system. The diskarray system 1 further has a communication interface (communication I/F) 80 between the diskarray switch 20 and the diskarray system configuration manager 70 , and also between the diskarray subset 10 and the diskarray system configuration manager 70 . A host 30 and the diskarray system 1 are connected by a host interface (host I/F)) 31 . The host I/F 31 is connected to the diskarray switches 20 of the diskarray system 1 . The diskarray switch 20 and the diskarray subset 10 inside the diskarray system 1 are connected by the diskarray interface (diskarray I/F 21 )
The hosts 30 and the diskarray subsets 10 are shown as four units each however this number is optional and is not limited. The hosts 30 and the diskarray subsets 10 may also be provided in different numbers of units. The diskarray switches 20 in this embodiment are duplexed as shown in the drawing. Each host 30 and each diskarray subset 10 are connected to both of the duplexed diskarray switches 20 by the respective host I/F 31 and a diskarray I/F 21 . Thus even if one of the diskarray switches 20 , the host I/F 31 or the diskarray I/F 21 is broken, the other diskarray switches 20 , the host I/F 31 or the diskarray I/F 21 can be utilized to allow access from the host 30 to the diskarray system 1 , and a high amount of usage can be achieved. However, this kind of duplication or duplexing is not always necessary and is selectable according to the level of reliability required by the system.
FIG. 2 is block diagram of a diskarray subset 10 of the first embodiment. The reference numeral 101 denotes the host adapter for interpreting the commands from the host system (host 10 ), executing the cache hit-miss decision and controlling the data transfer between the host system and the cache. The reference numeral 102 denotes the cache memory/shared memory that comprises the cache memory for performing high speed disk data access and a shared memory for storing data shared by the host adapters 101 and the lower adapters 103 . The reference numeral 104 denotes a plurality of disk units stored inside the diskarray subset 10 . Reference numeral 103 is the lower adapter for controlling a disk unit 104 and controlling the transfer of data between the disk unit 104 and the caches. Reference numeral 106 is the diskarray subset configuration manager to perform communications between the diskarray system configuration manager 70 and the overall diskarray system 1 , and also manage the structural parameter settings and reporting of trouble information, etc. The host adapter 101 , the cache memory/shared memory 102 , and the lower adapter 103 are respectively duplexed here. The reason for duplexing is to attain a high degree of utilization, just the same as with the diskarray switch 20 and is not always required. Each disk unit 104 is also controllable from any of the duplexed lower adapters 103 . In this embodiment, the cache and shared memories jointly utilize the same memory means in view of the need of low costs however the caches and shared memories can of course be isolated from each other.
The host adapter 101 comprises an host MPU 1010 to execute control of the adapter 101 , an host system or in other words a diskarray I/F controller 1011 to control the diskarray switches 20 and the connecting I/F which is the diskarray I/F 21 , and an host bus 1012 to perform communications and data transfer between the cache memory/shared memory 102 and host MPU 1010 and the diskarray I/F controller 1011 . The figure shows one diskarray I/F controller 1011 for each host adapter 101 however a plurality of diskarray I/F controllers 1011 can also be provided for each one host adapter.
The lower adapter 103 contains a lower MPU 103 to execute control of the lower adapter 103 , a disk I/F controller 1031 to control the disk 104 and interface which is the disk I/F, and a lower bus 1032 to perform communications and data transfer between the cache memory/shared memory 102 and host MPU 1030 and the diskarray I/F controller 1031 . The figure shows four diskarray I/F controllers 1031 for each lower adapter 103 however the—number of diskarray I/F controllers is optional and can be changed according to the diskarray configuration and the number of disks that are connected.
FIG. 3 is block diagram of the diskarray switch 20 of the first embodiment. The diskarray switch 20 contains a Managing Processor (MP) which is a processor for performing management and control of the entire diskarray switch, a crossbar switch 201 for comprising n×n mutual switch paths, a diskarray I/F node 202 formed for each diskarray I/F 21 , a host I/F node 203 formed for each host I/F 31 , and a communication controller 204 for performing communications with the diskarray system configuration manager 70 . The reference numeral 2020 denotes a path for connecting the diskarray I/F node 202 with the crossbar switch 201 , a path 2030 connects the host I/F node 203 and the crossbar switch 201 , a path 2040 connects with the other diskarray switch 20 and other IF for forming clusters, a path 2050 connects the MP 200 with a crossbar switch 201 .
FIG. 4 is a block diagram showing the structure of the crossbar switch 201 . A port 2010 is a switching port (SWP) for connecting the paths 2020 , 2030 , 2050 and cluster I/F 2040 to the crossbar switch 201 . The switching ports 2010 all have the same structure and perform switching control of the transfer paths to other SWP from a particular-SWP. The figure shows on SWP however identical transfer paths exist between all the SWP.
FIG. 5 is a block diagram showing the structure of the host I/F node 203 . In this embodiment, use of a fiber channel is assumed for both the diskarray I/F 21 and the host I/F 31 in order to provide a specific description. The host I/F 31 and the diskarray I/F 21 can of course be implemented with interfaces other than fiber channels. By utilizing an identical interface, the host I/F node 203 and the diskarray I/F node 202 can both have the same structure. In this embodiment, the diskarray I/F node 202 has the same structure as the host I/F node 203 as shown in the figure. Hereafter, the host I/F node 203 will be described by using an example. A Searching Processor (SP) searches for what frame to connect the fiber channel frame (hereafter simply called frame) to, an Interface Controller (IC) 2023 transmits and receives the frames with the host 30 (the diskarray subset 10 when using the diskarray I/F node 202 ), a Switching Controller (SC) 2022 performs conversion based on results found by the SP 2021 for frames received by the IC 2023 , a Switching Packet Generator (SPG) 2024 packetizes the frame converted by the SC 2021 into a configuration that can pass the crossbar switch 201 to transfer to other nodes, a Frame Buffer (FB) 2025 temporarily stores the received frame, an Exchange Table (ET) 2026 supervises use of exchange numbers for identifying a plurality of frame strings corresponding to a disk access request command (hereafter simply called command) from one host, and a Diskarray Configuration Table (DCT) 2027 stores structural information for a plurality of diskarray subsets 10 .
Each structural section of the diskarray switch 20 are preferably all comprised of hardware logic from the viewpoint of performance. However, program control utilizing general purpose processors is allowable for the SP 2021 and the SC 2022 functions if the specified performance can be achieved.
Each diskarray subset 10 has disk units 104 as one or a plurality of logical disk units. These logical disk units are referred to as Logical Units (LU). The LU need not correspond in a ratio of one to one, to the logical disk units 104 and one disk unit 104 can be comprised of a plurality of LU or one LU can comprise a plurality of disk units 104 . One LU is recognized as one disk device as seen externally of the diskarray unit 10 . In this embodiment, a logical LU is comprised further by a diskarray switch 20 and the host 30 functions to access this LU. In these specifications, when one LU is recognized as one LU by the host 30 , then the LU is called independent LU (ILU) and when a plurality of LUs are recognized as one LU by the host 30 , then the one LU recognized by the host 30 is called combined LU (CLU). FIG. 11 shows the address spatial relation for each level when one combined LU (CLU) is comprised of four LUs of four diskarray subsets. In the figure, the numeral 1000 indicates an LU address space for one combined LU (CLU) of the diskarray system 1 as seen from the host “# 2 ”, the numeral 1100 is an LU address space for the diskarray subset 10 , the numeral 1200 indicates an address space for the disk unit 104 (Here, shown only for the diskarray subset # 0 .) The LU for each diskarray subset 10 is comprised as a RAID 5 (Redundant Arrays of Inexpensive Disks Level 5) type diskarray, by four disk units 104 . Each diskarray subset 10 has an LU with respective capacities of nO, nI, n 2 , n 3 . Each diskarray switch 20 combines the address spaces held by these four LU to obtain a combined capacity (n 0 +n 1 +n 2 +n 3 ) and achieve a combined LU (or CLU) recognized from the host 30 .
In this embodiment, when for instance the host # 2 is accessing the region A 1001 , an access request is made specifying the region A 1001 , and this access request is converted by the diskarray switch 20 into a request for accessing the region A′ 1101 of the LU of the diskarray subset # 0 and this request then sent to the diskarray subset # 0 . This diskarray subset # 0 then performs access and mapping of the region A′ 1101 onto of the region A″ 1201 on the disk unit 104 . The mapping between the address space 1000 and the address space 1100 is based on structural information held in the DCT 207 in the diskarray switch 20 . The details of this processing are related later on. The mapping performed in the diskarray subset is a technical method already well known in the prior art so a detailed explanation is omitted here.
In this embodiment, the DCT 207 contains a Diskarray System Configuration Table and Diskarray Subset Configuration Tables. The structure of the Diskarray System Configuration Table is shown in FIG. 6A and the structure of the Diskarray Subset Configuration Tables are shown in FIG. 6B .
As shown in FIG. 6A , the Diskarray System Configuration Table 20270 has a Host-LU Configuration Table 20271 holding information showing the structure of the host-LU, and a Diskarray I/F Node Configuration Table 20272 showing the related connections of the diskarray subset 10 and the diskarray I/F node 202 of the diskarray switch 20 .
The Host-LU Configuration Table 20271 has LU information (LU Info.) relating to the condition and Host-LU of the diskarray subset 10 LU, which is information showing the LU type, CLU class, CLU stripe size and Host-LU indicating the affiliation of the LU and the Host-LU No. which is a number for identifying that LU. The LU Type in the table is information on the LU type showing that the Host-LU is a CLU or one LU. The CLU class is information showing the class is any one of “Joined”, “Mirrored” or “Striped” when the LU type of this Host-LU is shown to be a CLU. Here, “Joined” indicates as shown in FIG. 11 the CLU is one large memory space consisting of a group of LU connected together. As related later in the sixth embodiment, “Mirrored” indicated two LU achieved by a duplexed LU. As related later on in the seventh embodiment, “Striped” indicates an LU stored with data distributed into a plurality of these LU. When the CLU Stripe Size is shown by ‘Striped’ for the CLU class, then the striping size (A block size showing the units the data is distributed in.) is indicated. The status shown in the Condition box is one of four types consisting of “Normal”, “Warning”, “Fault” and “Not Defined”. Of these types, “Normal” indicates the Host-LU status is correct. “Warning” indicates contraction is being performed for reasons such as problems occurring in a disk unit corresponding to an LU comprising this Host-LU. “Fault” indicates that this Host-LU cannot be operated due to a problem in the diskarray subset 10 . The “Not Defined” type indicates the Host-LU is not defined for the corresponding Host-LU No. The LU Info contains information specifying the diskarray subset 10 affiliated with that LU, the LUN inside the diskarray subset, as well as information showing the size for LU that comprise this Host-LU. When the Host-LU is an ILU, then information for the sole LU is registered. When the Host-LU is a CLU, then information relating to all the respective LU comprising that CLU are registered. In the figure for instance, a Host-LU with a Host-LU No. of “0” is a CLU comprised from four LU that are LUN “0” of the diskarray subset “# 0 ”, LUN “0” of the diskarray subset “# 1 ”, LUN “0” of the diskarray subset “# 2 ”, and LUN “0” of the diskarray subset “# 3 ”. As can be seen in the table, this CLU is in the “Joined” CLU class.
The diskarray I/F node configuration table 20272 contains information on what diskarray I/F node 202 of diskarray switch 20 is connected to each port of the diskarray subset 10 connected to the diskarray I/F 21 . More specifically, this table holds the Subset NO. specifying the diskarray subset 10 , the Subset Port No. specifying the port, the Switch No. specifying the diskarray switch 20 connected to that port, and an I/F Node No., specifying the diskarray I/F node 202 of the diskarray switch 20 . When the diskarray subset 10 has a plurality of ports, information is set for each of those ports.
As shown in FIG. 6B the diskarray subset configuration table has a plurality of tables 202720 through 202723 corresponding to each of the diskarray subsets 10 . These tables include the RAID Group Configuration Table 202730 holding information showing the structure of the RAID Group inside the diskarray subset 10 , and the LU Configuration Table 202740 holding information showing the structure of the LU inside the diskarray subset 10 .
The RAID Group Configuration Table 202730 has a Group No. showing the number added to the RAID Group, a level showing the RAID Level of that RAID Group, and Disks with information showing the number of disk comprising that RAID Group. When that RAID Group is comprised of striping such as for RAID Level 0, 5, then information showing that Stripe Size is included. As shown for instance, in the figure in the table, a RAID Group “0” is a RAID Group comprised of four disk units. The RAID Level is 5 and the Stripe Size is SO.
The LU Configuration Table 202740 has an LU No. showing the number (LUN) added to the LU, a RAID Group showing how that LU is configured in the RAID Group, a Condition showing the status of the LU, a Size showing the size (Capacity) of that LU, a Port showing what ports of the diskarray subset 10 are capable of providing access, and also an Alt. Port showing port that can be used as alternates for that Port No. The status showing the condition are of four types just as with the Host-LU and comprise “Normal”, “Warning”, “Fault” and “Not Defined”. The port specified by information set in the Alt. Port is utilized when a problem occurs in the port specified with information set in the Port(item) however can also be used just for accessing the same LU from a plurality of ports.
FIG. 7 is a diagram of the frame for the fiber channel. A frame 40 of the fiber channel has an SOF (Start Of Frame) showing the beginning portion of the frame, a frame header 401 , a frame payload 402 which is a segment storing data for transfer, a CRC (Cyclic Redundancy Check) 403 which is a 32 bit error detection code, and a EOF (End Of Frame) showing the end of the frame. The frame header 401 has the structure shown in FIG. 8 . The ID of the frame transfer originator (S_ID), the ID for the frame transfer destination (D_ID), Exchange IDs respectively specified by the Exchange Originator and the Exchange Responder (OX_ID, RX_ID), and the Sequence ID for specifying the frame group within the exchange (SEQ_ID) are all stored in the frame header 401 . In this embodiment, the ID assigned as S_ID to the host 30 in the frame issued from the host 30 are also used as the ID assigned to the port of the diskarray switch 20 as the D_ID. One pair of Exchange ID (OX_ID, RX_ID) are assigned for one host command. When a plurality of data frames must be issued for the same Exchange, then an identical SEQ_ID is assigned to all of these data frames, and each one is identified as Sequence Count (SEQ_CNT). The Frame Payload 402 has a maximum length of 2112 byte and the contents stored in each type frame are different. In the case for instance of FCP_CMD frame related later on, the Logical Unit Number (LUN) of the SCSI and the Command Description Block (CDB) are stored as shown in FIG. 9 . The CDB contains the command bytes required to access the disk (diskarray), the transfer start logic address (LBA) and the transfer length (LEN).
The operation of the disk address system of this embodiment is described next.
In order to use the diskarray system, the setting of structural information of the diskarray subset 10 must be made for the diskarray switch 20 . The system administrator can acquired structural setup information for the diskarray switch 20 and the diskarray subset 10 from a management console 5 by way of the diskarray configuration manager 70 . The administrator can make different kinds of required entries of setup information such as logic unit structural setup for the desired system structure, RAID level settings, alternative path settings for use when trouble occurs. The diskarray configuration manager (means) 70 can receive that setting information, and transfer that setting information to the each diskarray subset 10 and diskarray switch 20 . The entry of setup information on the management console 5 is described separately in the fifth embodiment.
In the diskarray switch 20 , the communications controller 204 acquires the setup information and sets the structural information such as the address space information for each of the diskarray subsets 10 by means of the MP 200 . The MP 200 distributes the structural information of the diskarray subset 10 to the each of the host I/F nodes 203 and the diskarray I/F nodes 202 by way of the crossbar switch 201 . When the nodes 202 and 203 receive this information, the SP 2021 stored this structural information in the DCT 2027 . In the diskarray subset 10 , the diskarray subset configuration manager (means) 106 acquires the setup information and stores it in the shared memory 102 . The host MPU 1010 and the lower MPU 1030 refer to this setup information in the shared memory 102 and perform configuration management.
The operation when the read command is issued is described next for the diskarray system 1 with a host “# 2 ”. FIG. 10 is a model view showing the sequence of frames sent by way of the fiber channel during read operation from the host. FIG. 13A through 13C are flowcharts of the processing in the host I/F node 203 during write processing. In the following description, it is assumed the host “# 2 ” is accessing the storage area A 1001 in FIG. 11 . The actual storage area A″ corresponding to the storage area A 1001 is present in the address space of the disk unit # 2 comprising the LU for LUN=0 of the diskarray subset “# 0 ”. In the definition of the LU comprising the address space 1000 , in the Configuration Table 20271 , the LU Type is defined as “CLU” and the CLU Class is defined as “Joined”.
During reading of data, the host 30 issues a command frame “FCP_CMD” stored with the read command, to the diskarray switch 20 (arrow (a) in FIG. 10 ). The host I/F node “# 2 ” of the diskarray switch 20 receives the command frame “FCP_CMD” (step 20001 ) byway of the host I/F 31 from the IC 2023 . The IC 2023 transfers the command frame to the SC 2022 . The SC 2022 temporarily stores the received command frame in the Frame Buffer (FB) 2025 . At that time, the SC 2022 calculates the CRC of the command frame and inspect the received information to determine if it is correct. If an error is found in the CRC inspection, the SC 2022 reports the error to the IC 2023 . When the IC 2023 the error report from the SC 2022 , a report of the CRC error is made to the host 30 by way of the host I/F 31 (step 20002 ).
When the CRC inspection shows that the information is correct, the SC 2022 reads the frame held in the FB 2025 , recognizes this frame as the command frame, and analyzes the Frame Header 401 (step 20003 ). The SC 2022 then instructs the SP 2021 and registers the Exchange information such as S_ID, D ID, OX_ID in the ET 2026 (step 20004 ). Next, the SC 2022 analyzes the frame payload 402 and acquires the LUN and CDB specified by the host 30 (step 20005 ). The SC 2021 searches the DCT 2020 at the instruction of the SC 2022 and acquires the structural information of the diskarray subset 10 . More specifically, the SC 2021 searches the host-LU configuration table 20271 and finds information having a host-LU no. matching the LUN stored in the frame payload 402 that was received. The SC 2021 recognizes the structure of the Host-LU from the information set in the LU Type, and CLU class, and based on the information held in the LU Info., identifies the disk subset 10 that must be accessed and its LUN in the LU as well as the LBA in the LU. Next, the SC 2021 refers to the LU configuration table 202740 of the Diskarray Subset Configuration Table 202720 and confirms the connection port for the destination diskarray subset 10 , and acquires from the Diskarray I/F Node Configuration Table 20272 , the node No. of the diskarray I/F node 202 connected to that port. The SC 2021 in this way acquires the conversion information such as the No. LUN, LBA for recognizing the diskarray subset 10 and reports this information to the SC 2022 (step 20006 ). Next, using the acquired conversion information, the SC 2022 converts the LBA from the LUN and CDB of the frame payload 402 . Also, the D_ID of the frame header 401 is converted to the D_ID of the host I/F controller 1011 of the diskarray subset 10 . The S ID is not rewritten at this point (step 20007 ). The SC 2022 transfers the converted command frame and the diskarray I/F node No. connected to the corresponding diskarray subset 10 , to the SPG 2024 . The SPG 2024 generates a packet added with a simple expansion header 601 such as shown in FIG. 12 for the converted command that was received. This packet is called the Switching Packet (S Packet) 60 . The expansion header 601 of this S Packet 60 contains an added transfer originator (white node) No., a transfer responder node No. and a transfer length. The SPG 2024 send the generated S Packet 60 to the crossbar switch 201 (step 20008 ).
The crossbar switch 201 receives the S Packet 60 from the SWP 2010 connected to the host I/F node “# 2 ”. The SWP 2010 refers to the expansion header 601 of the S Packet 60 , establishes a path for carrying out switch control for the SWP connecting with the transfer responder node, and transfers the S Packet 60 to the transfer responder of the diskarray I/F node 202 (Here, the diskarray I/F node “# 0 ”). The SWP 2010 establishes a path whenever the S Packet 60 is received and releases that path when transfer of the S Packet 60 is finished. In the diskarray I/F node “# 0 ”, the SPG 2024 receives the S Packet 60 , removes the expansion header 601 and delivers the command frame portion to the SC 2022 . The SC 2022 writes its own ID in the S_ID of the frame header of the command frame that was accepted. Next, the SC 2022 instructs the SP 2021 to register the Exchange information such as the S_ID, D_ID, OX_ID, of the command frame as well as the frame transfer originator host I/F node No. into the ET 2026 , and transfers this command frame to the IC 2023 . The IC 2023 complies with instructions of the frame header 401 and transfers the command frame (arrow (b) of FIG. 10 ) to the connected diskarray subset 10 (Here, the diskarray subset “# 0 ”.).
The diskarray subset “# 0 ” receives the command frame “FCP_CMD” after conversion, in the diskarray I/F controller 1011 . The host MPU 1010 acquires the LUN and CDB stored in the frame payload 402 of the command frame and recognizes that the LEN length data from the LBA of the specified logical unit is the read command. The host MPU 1010 refers to the cache management information stored in the cache/shared memory 102 and performs cache miss-hit/hit identification. If a hit then the data is transferred from the cache 102 . If a miss then reading of data from the disk unit is necessary so that address conversion is implemented based on the structure of RAID 5 and a cache space is secured. Processing information required for read processing from the disk unit 2 is generated, and processing information for continued processing in the lower MPU 1030 is stored in the cache/shared memory 102 . The lower MPU 1030 starts processing when the processing information is stored in the cache/shared memory 102 . The lower MPU 1030 specifies an appropriate disk I/F controller 1031 and generates a read command to the disk unit 2 , and issued a command to the disk I/F controller 1031 . The disk I/F controller 1031 stored the data read from the disk unit 2 in the address specified by the cache/shared memory 102 and issues a completion report to the lower MPU 1030 . The lower MPU 1030 stores the processing completion report in the cache/shared memory 102 for reporting to the host MPU 1010 that processing was completed correctly. The host MPU 1010 restarts the processing when the processing completion report is stored in the cache/shared memory 102 and reports that read data setup is complete to the diskarray I/F controller 1011 . The diskarray I/F controller 1011 issues a “FCP_XFER_RDY” which is a data transfer setup completion frame on the fiber channel for the applicable diskarray I/F node “# 0 ” of the diskarray switch 20 (arrow (c) of FIG. 10 ). In the diskarray I/F node “# 0 ”, when the data transfer setup completion frame “FCP_XFER_RDY” is received, the SC 2022 acquires the reply responder Exchange ID (RX_ID) received from the diskarray subset 10 , specifies the S ID, D ID, OX_ID, instructs the SP 2021 and registers the RX ID in the applicable Exchange of the ET 2026 . The SC 2022 acquires the host I/F node No. of the transfer responder (transfer originator of the command frame) for the data transfer completion frame. The SC 2022 renders the S ID of this frame invalid and transfers it to the SPG 2024 . The SPG 2024 generates the S Packet as described previously and transfers the S Packet to the corresponding host I/F node “# 2 ” by way of the crossbar switch 201 .
When the SPG 2024 in the host I/F node “# 2 ” receives the S Packet of the data transfer completion frame, the expansion header of the S Packet is removed, and the “FCP_XFER_RDY” reproduced and delivered to the SC 2022 (step 20011 ). The SC 2022 instructs the SC 2021 , searches the ET 2026 and specifies the applicable Exchange (step 20012 ). Next, the SC 2022 investigates whether the frame is “FCP_XFER_RDY” (step 20013 ) and if “FCP_XFER_RDY”, instructs the SP 2021 to rewrite the originator Exchange ID (RX_ID) of ET 2026 . The value added to this frame is used as the originator Exchange ID (step 20014 ). The SC 2022 then converts the S_ID, D_ID of the frame header 401 to an appropriate value used by the ID of the host 30 and the ID of the host I/F node 203 (step 20015 ). The frame header 401 is thus converted to a frame corresponding to the host “# 2 ” by means of this processing. The IC 2023 issues a “FCP_XFER_RDY” data transfer completion frame for this host “# 2 ” (arrow (d) of FIG. 10 ) (step 20016 ).
The diskarray I/F controller 1011 for the diskarray subset “# 0 ” generates a data frame “FCP_DATA” for performing data transfer, and transfers it to the diskarray switch 20 (arrow (e) of FIG. 10 ). A limit of a maximum data length of 2 kilobytes for one frame is set to limit the data transfer length of the frame payload. When this data length is exceeded, data frames just equal to the required number are generated and issued. An identical SEQ_ID is assigned to all the data frames. Except for the case where a plurality of frames are generated for the same SEQ_ID (in other words SEQ_CNT changes), data frame issue is the same as for the data transfer setup completion frame. The diskarray switch 20 implements conversion of the frame header 401 for the data frame “FCP_DATA” just the same as for the data transfer setup completion frame. However, an RX_ID has previously been established when transferring the data frame so that the processing of step 20014 for the data transfer setup completion frame is skipped. After conversion of the frame header 401 , the diskarray switch 20 transfer the data frame to the host “# 2 ” (arrow (f) of FIG. 10 ).
Next, the diskarray subset “# 0 ” of the diskarray I/F controller 1011 generates a status frame “FCP_RSP” to perform the end status transfer and issued this frame to the diskarray switch 20 (arrow (g) of FIG. 10 ). In the diskarray switch 20 , the expansion header is removed from the S Packet by the SPG 2024 just the same as the processing for the data transfer setup completion frame, the “FCP_RSP” frame is recreated (step 20021 ) and the ET 2026 is searched by the SP 2021 and the Exchange information acquired (step 20022 ). The SC 2022 converts the frame based on this information (step 20023 ). The converted frame is transferred to the port “# 2 ” by the IC 2023 (arrow (h) of FIG. 10 ) (step 20024 ). Finally, the SP 2021 deletes the exchange information from the ET 2026 (step 20025 ).
The read processing is thus performed from the diskarray. In the write processing for the diskarray system 1 , only the transfer direction of the data frame is reverse and the processing is otherwise the same as the read processing.
The diskarray switch 20 as shown in FIG. 3 is provided with an intercluster I/F 2040 in the crossbar switch 201 . In the system structure shown in FIG. 1 , an intercluster I/F 2040 is not used. In the diskarray switch of this embodiment, other diskarray switches can be mutually connected as shown in FIG. 14 , utilizing the intercluster I/F 2040 . In this embodiment, only a total of eight diskarray subsets 10 and host 30 can be connected in a single diskarray switch 20 however a plurality of diskarray switches 20 can be mutually connected by utilizing the intercluster I/F 2040 and an increased number of diskarrays and hosts 10 can be connected. In the system shown in FIG. 14 for example, four diskarray switches 20 are used to connect up to a total of 32 units of the diskarray subset 10 and the hosts 30 , and data can be mutually transferred between these subsets and hosts. In this way, the number of diskarray subsets and the number of hosts that can be connected are increased according to the need for performance and disk capacity in this embodiment. Also, the capacity, performance and expandability of connection units can be drastically improved since connections can be made between the host—diskarray system by utilizing the necessary amount of host I/F transfer bandwidth.
In the embodiment as described above, even if the performance of one diskarray subset unit is limited by the internal bus and the internal MPU, mutual connections can be made between the host and the diskarray subset by utilizing a plurality of the diskarray subsets, by means of the diskarray switch. In this way, high performance can be achieved as a total diskarray system. Even if the performance of a diskarray subset is relatively low, high performance can be attained by utilizing a plurality of diskarray subsets. Accordingly, low cost diskarray subsets can be connected in just the required number to match the scale of the computer system, and a diskarray system can be constructed at a cost appropriate to the desired scale. Further, when improvement in performance of increasing the disk capacity is required, then the diskarray subsets can be added in just the required amount. Still further, since a plurality of diskarray switches can be utilized to connect an optional number of hosts and diskarray subsets, a drastic improvement can be made in the capacity, the performance or the number of units for connection, and a system with high expandability obtained. Even still further, reduced elements of a diskarray system itself of the conventional art can be utilized in this embodiment so that large scale software that was previously developed can be utilized without changes, thus reducing development costs and achieving a short development period.
(Second Embodiment)
FIG. 15 is a block diagram of the computer system of the second embodiment of this invention. In this embodiment, the structure differs from the first embodiment in that, in the host I/F node of the diskarray switch, only the frame header 401 is converted, the frame payload 402 is not operated and also in that the diskarray switch, the host I/F and the diskarray I/F are not duplexed (duplicated). The elements of the structure are therefore not greatly different from the first embodiment and a detailed description of those similar sections is omitted.
In FIG. 15 , the diskarray subsets 10 are comprised of a plurality of logical units (LU) 110 . Each LU 110 is configured as an independent LU. The serial numbers assigned to the LUN in the LU 110 inside the diskarray subsets 10 generally start from 0 (zero). Therefore, when showing to a host 30 , consecutive LUN for all LU 110 in the diskarray system 1 , then converting the LUN field for the frame payload 402 is necessary, the same as in the first embodiment. In this embodiment, the LUN of the diskarray subsets 10 are shown unchanged to the host 30 , so conversion of the frame payload 402 is not necessary and the control of the diskarray switches is extremely simple.
In the diskarray switches of this embodiment, it is assumed that a specified diskarray subset 10 can be accessed for each host I/F node 203 . When one host I/F 31 is used in this case, only the LU 110 in one diskarray subset 10 can be accessed. When accessing LU 110 in a plurality of diskarray subsets 10 from one host unit is needed, then that host is connected to a plurality of host I/F nodes 203 . Further, when setting access of LU 110 of one diskarray subset 10 from a plurality of host 30 , then loop topology or fabric topology can be utilized in the same host I/F node 203 to connect to the plurality of hosts 30 . When configured in this way, during access of one LU 110 from one host 30 , a diskarray subset 10 can be set for each D_ID of the host I/F node 203 so that the LUN of each LU can be shown as is, to the host 30 .
Since in this embodiment, the LU of each LU 110 inside the diskarray subsets 10 can be shown unchanged to the host 30 for the above related reasons, then conversion of the LUN is no longer required in the diskarray switch 20 . Accordingly, when the diskarray switch 20 receives a frame from the host 30 , only the frame header 30 is converted the same as in the first embodiment, and the frame payload 402 is transferred without conversion to the diskarray subset 10 . In the operation of each section of this embodiment, excluding the fact that the conversion of the frame payload 402 is not performed, the embodiment is the same as the first embodiment so that a detailed explanation of the identical sections is omitted. The diskarray switch 2 can be easily developed in this embodiment.
(Third Embodiment)
In the second embodiment, in the host I/F node of the diskarray switch, only the frame header 401 is converted, however in the third embodiment described hereafter, frame conversion, including the frame header is not performed. The computer system of this embodiment is configured the same as the computer system in the first embodiment as shown in FIG. 1 .
In the first and second embodiments, the internal structure of the diskarray system 1 such as the number of diskarray subsets 10 and the configuration of the LU 110 are concealed from the host 30 . The host 30 therefore sees the entire diskarray system 1 as one storage device. In contrast, in this embodiment, the diskarray subset 10 is revealed to the host 30 , and the host 30 directly uses the D_ID of the frame header as the port ID for the diskarray subset. By this arrangement the diskarray switch can control frame transfer just by complying with the frame header information, and the fabric of the fiber channel in the conventional art can be used instead of the diskarray switch 20 to achieve an equivalent switch device.
The diskarray system configuration manager (means) 70 communicates with the communication controller 106 of the diskarray subset 10 as well as the communication means 204 of the diskarray switch 20 and acquires or sets structural information of the diskarray subsets 10 and the diskarray switches 20 .
The diskarray switches 20 have a structure basically the same as the diskarray switches of the first embodiment as shown in FIG. 3 . However, in this embodiment, the frame header information for frames issued from the host 30 is used unchanged to control frame transfer so that the conversion function of the first and second embodiments, in which a frame header is achieved by a DCT 2027 , SC 2022 , SPG 2024 of the diskarray I/F node 202 and host I/F node 203 of the diskarray switch, is not necessary. The crossbar switch 201 in the diskarray switch 20 , performs transfer of fiber channel frames between the host I/F node 203 , and the diskarray I/F node 202 , according to the frame header information.
In this embodiment, to achieve total management of the diskarray system structure with the diskarray system configuration manager 70 , a diskarray management table (hereafter this table is called DCT, is provided in the diskarray system configuration manager 70 . The DCT comprising the diskarray system configuration manager 70 consists of a group of two tables; a Diskarray System Configuration Table 20270 and a Diskarray Subset Configuration Table 202720 - 202723 . The host-LU in this embodiment are all comprise as one LU so that the “LU Type” in the Host-LU Configuration table 20271 are all “ILU”, and the “CLU Class” and CLU Stripe Size” are not significant.
The administrator operates the management console 5 , communicates with the diskarray system configuration manager 70 and acquires information such as the number of disk units, and disk capacity of the diskarray subset 10 , and performs setting of the LU 110 of the diskarray subset 10 and setting of the RAID level. Next, the administrator communicates with the diskarray system configuration manager 70 from the management console 5 , controls the diskarray switch 20 and sets related information among the host 30 and the diskarray subsets 10 . This operation establishes the structure of the diskarray system 1 and allows LU 1 to be seen as the administrator wishes, from the host 30 . The diskarray system configuration manager 70 saves the above setting information, verifies the configuration according operation by the administrator and performs changes in the structure (configuration).
In this embodiment, once the diskarray system 1 is configured, a plurality of diskarray systems 1 can be handled the same as one diskarray system and without making the administrator aware of the presence of the diskarray switch 20 . Further in this embodiment, the diskarray subsets 10 and the diskarray switches 20 can be operated together by means of the same operating environment and confirming their configuration (or structure) and making changes in the configuration is also simple. Still further in this embodiment, when substituting the diskarray system of this embodiment with a diskarray system used in the conventional art, no changes are made in the host 30 settings, and the structure of the diskarray system 1 can work with the diskarray system structure used up until then, and interchangeability can be maintained.
(Fourth Embodiment)
A fiber channel was used in the host I/F in the first through third embodiments described above. In the embodiment hereafter described, an interface other than the fiber channel might also be used.
FIG. 16 is a block diagram of the IC (Interface Controller) 2023 inside the host I/F node 203 , when the host I/F is a parallel SCSI. An SCSI protocol controller (SPC) 20230 performs the protocol control of the parallel SCSI. A fiber channel protocol controller (FPC) 20233 performs control of the fiber channel. A protocol exchanging processor (PEP) 20231 converts the protocol of the serial SCSI of the fiber channel and the parallel SCSI. A buffer (BUF) 20232 temporarily stores the data of the protocol being converted.
The host 30 in this embodiment, issues a SCSI command to the diskarray I/F node 203 . In the case of a read command, the SPC 20230 stores this in the BUF 20232 and reports reception of the command by breaking into the PEP 20231 . The PEP 20231 uses the command stored in the BUF 20232 , and converts the command to FPC 20233 and sends it to the FPC 20233 . When the FPC 20233 receives this command, it converts the command into a frame configuration and delivers it to the SC 2022 . At this time, the Exchange ID, Sequence ID, Source ID and Destination ID are added to PEP 20231 capable of the following processing. The remaining command processing is performed the same as in the first embodiment. When the setup of data is complete, the data array subset 10 issues a data transfer setup completion frame, and after the data transfer ends correctly, implements issue of a status frame. In the period from the diskarray subset 10 to the IC 2023 , while the frame header 401 and the frame payload 402 are being converted as required, the transfer of each frame is performed. The FPC 20233 of the IC 2023 receives the data transfer setup completion frame, then receives the data and stores it in the BUF 20232 and if the transfer has ended correctly, receives the status report, and breaks into the PTP 20231 to report that transfer of data is complete. When the PTP 20231 receives the break-in (interruption), the SPC 20230 starts up and instructs the start of data transfer to the host 30 . The SPC 20230 transmits the data to the host 30 , and after confirming normal completion, interrupts the PTP 20231 to report the data transfer ended correctly.
A parallel SCSI was used as an example here of a host I/F other than a fiber channel however other interfaces can be implemented such as for ESCON in the same manner as a host I/F to the main frame. Host I/F nodes corresponding for instance, to the fiber channel, parallel SCSI and ESCON can be provided as the host I/F node 203 of the diskarray switch 20 so that all kinds of so-called open systems such as personal computers and work stations can be connected with the main frame to one diskarray system 1 . In this embodiment, a fiber channel was utilized as the diskarray I/F in the first through the third embodiments however the desired optional I/F can also be used as the diskarray I/F.
(Fifth Embodiment)
A method for configuration management of the diskarray system 1 is described using the fifth embodiment. FIG. 17 is a system diagram of this embodiment. A total of four host 30 units are provided in this embodiment. The I/F 30 connecting between the host “# 0 ”, “# 1 ” and the diskarray system 1 is a fiber channel, the host “# 2 ” and the diskarray system 1 are connected by a parallel SCSI (Ultra SCSI). The host “# 3 ” and the diskarray system 1 are connected by a parallel SCSI (Ultra2SCSI). The connection to the diskarray switch 20 of the parallel SCSI is performed in the same way as the fourth embodiment. The diskarray system 1 has four diskarray subsets 30 . The diskarray subset “# 0 ” has four independent LU. The diskarray subset “# 1 ” has two independent LU. The diskarray subset “# 2 ” and the diskarray subset “# 3 ” are comprised of one combined LU (CLU). In this embodiment, just the same as the first embodiment, the diskarray subset 10 is concealed from the host 30 , and the frame of the fiber channel is converted. The LUN assigned to each LU, in order from the diskarray subset “# 0 ” are seven, LUN=0, 1, 2, . . . to 6.
FIG. 18 is a screen view showing on the management console screen 5 . This figure shows the logical connection structure corresponding to the logical units (LU) and the host I/F 31 . The logical connection configuration screen 50 shows the information 3100 relating to each host I/F 31 , the information 11000 relating to each LU 110 , and the relation of the diskarray subset 10 and the LU 110 . Information relating to the host I/F 31 includes the I/F type, the I/F speed and status, etc. Information relating to the LU 110 such as the storage subset No, LUN, capacity, RAID level, status, and information are displayed. The administrator refers to this information and can easily manage the configuration of the diskarray system 1 . The lines drawn between the host I/F and the LU on the logical connection configuration screen 50 shows the LU 110 accessible by way of each of the host I/F 31 . Those LU 110 to which a line is not drawn from the host I/F cannot be accessed from the host 30 connected to that host I/F. The data configuration that is handled differs according to the host 30 , and also differs according to the user so that appropriate restrictions on access must be provided in order to maintain security. The administrators setting the system thereupon utilize this screen, to implement restrictions on access by granting or denying access between the host I/F and each LU 110 . In the figure, the LU “# 0 ” can be accessed from the host I/F “# 0 ” and “# 1 ” however, the LU “# 0 ” cannot be accessed from the host I/F “# 2 ” and “# 3 ”. The LU “# 4 ” can only be accessed from the host I/F “# 2 ”. In order to implement these kind of access restrictions, the access restriction information is sent from the diskarray system configuration manager 70 to the diskarray switch 20 . The access restriction information sent to the diskarray switch 20 is distributed to each host I/F node 203 and registered in the DCT 2027 of each host I/F node 203 . When an LU search check command has been issued for an LU with access restrictions, the host I/F node 203 performs a search of the DCT 2027 and if a response is not obtained to the search command or if an error is returned, then that LU is no longer recognized (authorized) from the host. The Test Unit Ready command or the Inquiry command are typically used when in the case of SCSI protocol as search command for the presence of an LU. Since read/write cannot be implemented without this search command, restrictions on access are easy to apply. In this embodiment, access restrictions are applied to each host I/F 31 however by extending this the implementing of access restrictions on each host 30 is easily accomplished. Further, the host I/F 31 , host 30 , or an address space can be specified, and access restrictions can be applied according to the type of command so that read only, write only, read and write permit, and read/write prohibit are enforced. In this case, the host I/F No, the host ID, the address space or the restriction command are specified as the access restriction information and the restriction set in the disk access switch 20 .
Next, the addition of another diskarray subset 10 is described. When adding a new diskarray subset 10 , the administrator connects the diskarray subset 10 to be added, to an empty I/F node 202 of the diskarray switch 20 . The administrator next operates the management console 5 and presses the “Show Latest Status” button 5001 displayed on the logical connection configuration screen 50 . A picture showing the diskarray subsets not yet set appears on the screen (not shown in drawing) in response to pressing the button 5001 . When the picture for this diskarray subset is selected, the setup screen for the diskarray subsets then appears. The on this setup screen, the administrator executes the various settings for the newly added diskarray subset. Items set on this screen include the RAID level and the LU configuration. Next, on switching to the logical connection configuration screen of FIG. 19 , the new diskarray subset and the LU appear. From here on, the settings for restricting access for the host I/F 31 are made, and the “Setup Execution” button 5002 is pressed, access restriction information, as well as diskarray subsets, and LU information for the diskarray switch 20 are transferred and the settings enabled. The procedure when adding a LU 110 to the diskarray subset 10 is performed the same as in the above related procedure. The deletion of the diskarray subset, and the LU are also performed with approximately the same procedure. One point of difference is that the administrator selects the sections for deletion on the screen and presses the “Delete” button, and the deletion is implemented after making an appropriate check. Thus, by utilizing the management console 5 , the administrator can collectively manage the entire diskarray system.
(Sixth Embodiment)
Next the mirroring process by means of the diskarray switch 20 is described utilizing the sixth embodiment. The mirroring described here, is a method to support duplexed (duplicated) writing by means of two independent LU of two diskarray subsets, and duplicating including up to the controller of the diskarray subset. The reliability therefore is different from the method duplexing only the disks.
The system configuration (structure) of this embodiment is the same as shown in FIG. 1 . In the configuration of FIG. 1 , the diskarray subsets “# 0 ” and “# 1 ” are provided with completely the same LU configuration. These two diskarray subsets are seen from the host 30 as one diskarray. For reasons of convenience, the pair No. of the diskarray subset that was mirrored is called “# 01 ”. Also, a mirroring pair is formed by the LU “# 1 ” and the LU “# 0 ” of the diskarray subset, and this LU pair is conveniently named, LU “# 01 ”. Information for managing the LU# 01 is set as “Mirrored” in the CLU class on the Host-LU Configuration Table 20271 of the DCT 2027 , and information relating to LU# 0 and LU# 1 is set as the LU Info. The configuration of the other sections is the same as in the first embodiment.
The operation of each section of this embodiment is largely the same as the first embodiment. Hereafter, the points differing from the first embodiment are explained mainly with the operation of the host I/F node of the diskarray switch 20 FIG. 19 is a model diagram showing the sequence of frames being transferred in the write operation of this embodiment. FIGS. 20A through 20D are flowcharts showing the processing in the host I/F node 203 during the write operation.
In the write operation, the write command frame (FCP_CMD) issued by the host 30 is received by the IC 2023 (arrow (a) of FIG. 19 ) (step 21001 ). The write command frame received by the IC 2023 is processed the same as in steps 20002 - 20005 in the write operation described for the first embodiment (step 21002 - 21005 ). The SC 2022 searches the DCT 2027 using the SP 2021 and verifies that there is a write access request to the LU “# 01 ” of the mirrored diskarray subset “# 01 ” (step 21006 ). The SC 2022 makes duplicates of the command frame that was received in FB 2025 (step 21007 ). The SC 2022 converts the command frame based on the structural information set in the DCT 2027 , and makes separate command frames for both the LU “# 1 ” and the LU “# 0 ” (step 21008 ). The LU “# 0 ” is here called the master LU, and the LU “# 1 ” the slave LU. The command frames are also called respectively the master command frame and the slave command frame. Both of these separate frames are stored in the exchange information in ET 2026 , and a command frame issued for the diskarray subset “# 0 ” and the diskarray subset “# 1 ” (arrows (b 0 )(b 1 ) of FIG. 19 ) (step 21009 ).
The diskarray subsets “# 0 ” and “# 1 ” receive the command frames and the respective, independent, data transfer setup completion frames “FCP_XFER_RDY” are distributed to the diskarray switch 20 “(arrows (c 0 )(c 1 ) of FIG. 19 ). In the diskarray switch 20 , the data transfer setup completion frames transferred by the same processing as in steps 20011 - 20013 of the read operation in the first embodiment, are processed in the host I/F node 203 (step 21011 - 21013 ). At the stage that the data transfer setup completion frames from each diskarray subsets are arranged (step 21014 ), the SC 2022 converts the master data transfer setup completion frames (step 21015 ), and after frame conversion by the 1 C 2023 sends the frame to the host 30 (arrow (d) of FIG. 19 ) (step 21015 ).
After receiving the data transfer setup completion frame, the host 30 sends the data frame (FCP_DATA) to the diskarray switch 20 (arrow (e) of FIG. 19 ). When the data frame from the host 30 is received by the 1 C 2023 (step 21031 ), the read command frame and the write command frame are both stored in the FB 2025 , and a CRC check and frame header analysis are performed (steps 21032 , 21033 ). The ET 2026 is searched by the SP 2021 based on the frame header analysis results, and the Exchange information is acquired (step 21034 ). The SP 2022 makes duplicates the same as during the write command frame (step 21035 ). One copy is sent to the LU “# 0 ” of the diskarray subset “# 0 ” and the other is sent to the LU “# 1 ” of the diskarray subset “# 1 ” (arrow (f 0 )(f 1 ) of FIG. 19 ) (step 21037 ).
The diskarray subsets “# 0 ” and “# 1 ” receive each of the data frames, respectively write these frames in the disk unit 104 , and set the status frame (FCP_RSP) to the diskarray switch 20 . When the SP 2022 receives the status frames from the respective diskarray subsets “# 0 ” and “# 1 ”, their respective expansion headers are removed from their status frames, the frame header restored and the exchange information acquired from the ET 2026 (step 21041 , 21042 ). When the status frames from both the diskarray subsets “# 0 ” and “# 1 ” are arranged (step 21043 ), conversion of the master status frame from the LU “# 0 ” is performed (step 21044 ) after checking that the status has completed correctly, and the slave status frame is deleted (step 21045 ). Then, the IC 2023 sends a command frame to the host to report correct completion (arrow (h) of FIG. 19 ) (step 21046 ). Finally, the SP 2021 deletes the exchange information of ET 2026 (step 21047 ).
The write processing in the mirrored structure is thus completed. The read processing for the mirrored LU “# 01 ” differs only in the direction of data transfer, and is performed largely the same as the above described write processing except that the issue of a read command to two diskarray subsets is not necessary, and a command frame can be issued just to either diskarray subset. A command frame for instance can be issued mainly to the master LU however for high speed operation, methods such as alternate issue of command frames for both the master/slave LU will prove effective in distributing the load.
In the above related processing, in steps 21014 and step 21043 , a reply from the two diskarray subsets LU “# 0 ” and “# 1 ” is awaited, both synchronized with and the process then proceeds. With this kind of control, handling of errors is simple since the process proceeds after verifying the success of the processing for both of the diskarray subsets. On the other hand this kind of control has the drawback performance declines since the overall processing speed depends on which of the replies is slower. To resolve this problem, in the diskarray switch, control such as by proceeding to the next process without waiting for a reply from the diskarray subset or a “Asynchronous type” control that proceeds to the next process at the point where a reply from either one of the diskarray subsets is received are possible. The frame sequence when this asynchronous type control is used is shown by the dashed arrow lines in FIG. 19 . In the frame sequence shown by the dashed arrow lines, the sending of the data transfer setup complete frame to the host performed in step 21016 , is implemented after the processing in step 21009 , without waiting for the data transfer setup complete frame from the diskarray subset 10 . In this case, the data transfer setup complete frame sent to the host, is generated by the SC 2022 of the diskarray switch 20 (dashed arrow line (d′)). The data frame from the host 30 is transferred to the diskarray switch 20 at the timing shown by the dashed arrow line (e′). In the diskarray switch 20 , this data frame is temporarily stored in the FB 2025 . The SC 2022 makes a reply after receiving the data transfer setup complete frame from the diskarray subset 10 , and transfers the data frame held in the FB 2025 (dashed arrow lines (f 0 ′), (fl′)) per the data transfer setup complete frame sent from the diskarray subset 10 . The completion report to the host 30 from the diskarray switch 20 is performed (dashed arrow line (h′)) when there is a report (dashed arrow lines (g 0 ′), (gl′)) from both of the diskarray subsets 10 . This kind of processing can shorten the processing time by an amount equal to the time Ta shown in FIG. 19 .
The following processing is implemented when an error occurs during frame transfer between the diskarray subset 10 and the diskarray switch 20 . When the process being implemented is write processing, then a retry process is performed on the LU in which the error occurred. If the retry process is a success, then the process continues unchanged. However, when the retry process fails after a preset number of retries, then the diskarray switch 20 prohibits access to this diskarray set 10 (or LU) and information showing this prohibition is registered in the DCT 2027 . The diskarray switch 20 also reports this information to the diskarray system configuration manager 70 by way of the communication controller 204 and the MP 200 . The diskarray system configuration manager 70 then issues an alarm to the management console 5 in response to this report. The administrator can thus recognize that trouble has occurred. Afterwards, the diskarray switch 20 continues the operation by utilizing a normal diskarray subset. The host 30 also continues processing without recognizing that an error has occurred.
This embodiment utilizes a mirror configuration in a two unit diskarray subsystem to that the disk is made more resistant to problems that occur. The resistance of the diskarray controller, diskarray I/F, and the diskarray I/F node can also be improved, and the reliability of the overall diskarray system can be improved without taking measures such as duplexing (duplicating) the internal buses.
(Seventh Embodiment)
In the seventh embodiment, a method is described for combining three or more diskarray subsets 10 and configuring them into one logical diskarray subset group. In this embodiment, data is distributed and stored into a plurality of diskarray subsets 10 . Distributing and storing the data in this way allows distributing the access to the diskarray subsets, to prevent the access being concentrated in a particular diskarray subset so that the throughput of the total group is improved. A diskarray switch is used in this embodiment to implement this kind of striping.
An address map of the disk address system 1 of this embodiment is shown in FIG. 21 . The address space for the diskarray subsets 10 is striped at a stripe size S. The address spaces of the disk address system 1 as seen from the host are distributed into the diskarray subsets “# 0 ”, “# 1 ”, “# 2 ” and “# 3 ”. The size of the stripe size S is optional however should not be reduced very much. If the stripe size S is too small, the possibility of the occurrence of the stripe crossover, which is a phenomenon that the target data attaches to a plurality of stripes across diskarray subsets, will be risen and overhead may occur in the process. When the stripe size S is set large, then the probability that stripe crossover will occurs diminishes, so a large stripe size S is preferable in terms of improved performance. The number of LU that can be set is optional.
Hereafter, the operation of the host I/F node 203 in this embodiment is described while referring to the operation flowchart shown in FIG. 22 and points differing from the first embodiment are described. In this embodiment, as information relating to the striped HostLU, “Striped” is set in the CLU Class and “S” is set in the CLU Stripe Size, in the Host-LU Configuration Table 20271 of the DCT 2027 .
When a command frame is issued from the host 30 , the diskarray switch 20 receives this command frame with the IC 2023 of the host I/F node 203 (step 22001 ). The SC 2022 accepts this command frame from the IC 2023 , searches the DCT 2027 using the SP 2021 and verifies that striping is necessary (step 22005 ). Next, SC 2022 searches the DCT 2027 using the SP 2021 , finds from the structural information containing the stripe size S, the stripe No. for the stripe belonging to the data being accessed, and designates what diskarray subset 10 this stripe is stored in (step 22006 ). Stripe crossover may possible occur at this time however this processing in such a case is related later. When no stripe crossover occurs, the SC 2022 implements conversion of the command frame (step 22007 ) based on SP 2020 calculation results, and stores the exchange information in the ET 2026 (step 22008 ). The subsequent processing is the same as for the first embodiment.
When stripe crossover has occurred, the SP 2021 generates two command frames. These frames are generated for instance, by duplicating the command frame issued from the host 30 . New settings are made such as for the frame header and frame payload of the generated command frame. After duplicating the command frame in SC 2022 , conversion can also be implemented the same as in the sixth embodiment however in this embodiment is newly made by SP 2022 . When the two command frames are made, the SC 2022 sends these frames to the respective diskarray subsets 10 . Data transfer is then performed the same as in the first embodiment. The point in this embodiment differing from the first embodiment is that the data itself must be transferred between one host 30 and two diskarray subsets 10 . In the read process for instance, the data frame transferred from the two diskarray subsets 10 , must be transferred to all the hosts 30 . The SC 2022 at this time, complies with the information registered in the ET 2026 , and adds the appropriate exchange information, in the appropriate order to the data frame transferred from the diskarray subset 10 and sends this to the host 30 . In the write process, two data frames are made, the same as for the command frame, and transferred to the applicable diskarray subset 10 . The sequential control of the data frames at the host or the diskarray subset is called the “Out of Order” function. This “Out of Order” function is not required if the configuration is compatible with nonsequential processing. Finally, when all data transfer is complete, and the diskarray switch 20 has received the status frames respectively from the two diskarray subsets 10 , the SP 2021 (or the SC 2022 ) makes a status frame for the host 30 , and the IC 2023 sends this status frame to the host 30 .
This embodiment as described above, is capable of distributing the access (load) into a plurality of diskarray subsets, so that along with improving the total throughput, the access latency can be reduced.
(Eighth Embodiment)
Next, the duplicating operation between the two diskarray systems (or the diskarray subsets) is described using the eighth embodiment. In the system described here, one of two diskarray systems is installed at a remote location to provide recovery assistance in case of damage to the other diskarray system due to a natural or man-made calamity, etc. This kind of countermeasure for dealing with damage from disasters is referred to as disaster recovery and the making of copies performed with the diskarray system at the remote location is referred to as remote copy.
In the mirroring as described in the sixth embodiment, the mirror function is achieved with the diskarray subsets 10 installed at largely the same location geographically so that diskarray I/F 21 can use a fiber channel. However when diskarrays (diskarray subsets) are performing remote copy at remote locations in excess of 10 kilometers, then a fiber channel cannot be used to transfer a frame unless relay equipment is added. A mutual distance of some several hundred kilometers is used during disaster recovery so that use of fiber channels for connecting between diskarrays is impractical. Therefore methods such as satellite communications or high speed public telephone lines with ATM (Asynchronous Transfer Mode) are utilized.
FIG. 23 is a block diagram of the disaster recovery system of the embodiment. In the figure, the reference numeral 81 denotes site A, 82 denotes site B. Both sites are installed at geographically remote locations. Reference numeral 9 denotes a public telephone line, through which the ATM packet passes. The site A 81 and the site B 82 each have a diskarray system 1 . In this case, the site A 81 is the normally used site, while site B 82 is used as the remote disaster recovery site when site A 81 is down due to a disaster. The contents of the diskarray subset “# 0 ” and “# 1 ” of the diskarray system 10 of the site A 81 are copied to the remote copy diskarray subset “# 0 ” and “# 1 ” of the diskarray system 10 of site B 82 . The node for connection to the remote site from among the I/F nodes of the diskarray switch 20 is connected to the public telephone line 9 by utilizing ATM. This node is called the ATM node 205 . The ATM node 205 is configured the same as the host I/F node shown in FIG. 5 , and the IC 2023 performs ATM—fiber channel conversion. This conversion is achieved by same method as the SCSI—fiber channel conversion in the fourth embodiment.
The remote copy process in this embodiment is similar to the mirroring process in the sixth embodiment. The points differing from the mirroring process of the sixth embodiment are explained next. When the host 30 issues a write command frame, the diskarray system 10 of site A 81 performs frame duplicating the same as in the sixth embodiment, and transfers one of the copied (duplexed) frames to its own diskarray subset 10 . The other frame is converted from a fiber channel frame to an ATM packet by the ATM node 205 and sent to the site B 82 by way of the public telephone line 9 . At the site B 82 , the ATM node 205 of the diskarray switch 20 receives this packet. The 1 C 2023 of the ATM node 205 , restores the fiber channel frame from the ATM packet, and transfers the fiber channel frame to the SC 2022 . The SC 2022 implements frame conversion the same as when the write command was received from the host 30 and transfers the frame to the remote copy diskarray subset. From hereon, fiber channel—ATM conversion is performed for all the data transfer setup completion frames, data frames and status frame, and by implementing the same frame transfer process, remote copy can be achieved. When the read command frame was issued from the host 30 , the diskarray switch 20 transfers the command frame only to the diskarray subset 10 only for its own site and reads this data only from the diskarray subset 10 of its own site. The operation at this time is the same as in the first embodiment.
This embodiment is capable of making backups of user data in real-time and providing recovery assistance when damage has occurred to a diskarray system site due to a disaster, etc.
(Ninth Embodiment)
The combining of a plurality of LU in one diskarray subset 10 is described next. The disk storage device for a main frame for instance, has a logical volume size set to a maximum value of 2 GB in order to maintain interchangeability with the previous system. When using this kind of diskarray system as an open system, the LU receive the same restrictions on the logical volume size, so that the hosts see this configuration as a large number of small size LU. This kind of method has the problem that operating the system is difficult when the system has developed to a high capacity level To deal with this problem, a method was contrived for combining these logical volume (in other words LU) units into one large combine LU (CLU) structure by means of the diskarray switch 20 . The forming of a combined LU (CLU) is achieved in this embodiment by the diskarray switch 20 . The combining of LU in this embodiment is the same as the forming of combined LU by means of a plurality of diskarray subsets 10 in the first embodiment. The differing point is only that in this embodiment, a plurality of LU are combined within the same diskarray subset 10 . The operation as a diskarray system is completely the same as in the first embodiment.
By combining a plurality of LU in the same diskarray subset 10 in this way, to form one large LU, a diskarray system is achieved having excellent operability, reduced management cost and in which there is no need for the host to manage a large number of LU.
(Tenth Embodiment)
Next, a method for setting alternative paths by means of the diskarray switch 10 is explained while referring to FIG. 24 . The structure of each section in the computer system shown in FIG. 24 is the same as in the first embodiment. Here, it is assumed that the two hosts 30 are accessing the diskarray subset 10 by utilizing the different diskarray I/F 21 . The diskarray subsets, the host I/F nodes 203 of the diskarray switch 20 and the diskarray I/F nodes 202 in the figure are shown only in the numbers required for this explanation. The diskarray subset 10 has the same structure as shown in FIG. 2 , with two diskarray I/F controllers each connected to one diskarray switch 20 . An alternative path for the diskarray I/F 21 is set in the DCT 227 of each node of the diskarray switch 20 . The alternative path is a substitute path to provide access in the event trouble occurs on a particular path.
Here, the alternative path for the diskarray I/F “# 0 ” is set as the diskarray I/F “# 1 ”, while the alternative path for the diskarray I/F “# 1 ” is set as the diskarray I/F “# 0 ”. Alternative paths are set in the same way respectively for the host adapter in the diskarray subset 10 , the cache memory/shared memory, and the lower adapter.
Next, the setting of the alternative path is described, assuming that a problem has occurred and the path connecting the diskarray I/F 21 to the host adapter “# 1 ” of the diskarray subset 1 is broken or unusable as shown in FIG. 24 . At this time, the host “# 1 ” utilizing the diskarray I/F 21 where the problem occurred, is unable to access the diskarray subset 10 . The diskarray switch 20 detects an abnormality in the frame transfer with the diskarray subset 10 and when the path cannot be restored after retry processing is implemented, verifies a problem to have occurred on this path. When a problem occurs on the path, the SP 2021 registers the information that a problem has occurred in the diskarray I/F “# 1 ” in the DCT 2027 . Hereafter, the SC 2022 of the host I/F node 203 functions to transfer frames from the host “# 1 ” to the diskarray I/F node 202 connected to the diskarray I/F node “# 0 ”. The host adapter 101 of the diskarray subset 10 continues the processing of the command from the host “# 1 ”. The diskarray switch 20 reports the occurrence of a problem to the diskarray system configuration manager 70 , and the occurrence of a problem is then reported to the administrator by means of the diskarray system configuration manager 70 . The embodiment described above, can therefore switch to an alternative path when a problem occurs on a path, without this switch being recognized by the host and render the setting of substitutes on the host side unnecessary. Thus the utilization of the system can be improved.
In this invention as described above, a storage system can be achieved that easily improves the storage device expandability, and reliability according to various requirements and the scale of the computer system. The above explanations of the each of the embodiments all utilized a diskarray system having a disk device. However, this invention is not limited to use of a disk device as a storage media and is also applicable to optical disk devices, tape devices, DVD devices and semiconductor storage devices, etc. | This invention provides a user or an operator with a management apparatus or method for displaying logical connection information between an interface connected to a computer and a switch and a storage system or a logical unit in the storage system in a virtual storage system, wherein the switch receives a first access request from said computer, converts said first access request to a second access request to one of said plural storage systems, and sends said second access request to one of said plural storage systems or one logical unit. | 85,993 |
[0001] This application claims the benefit of Taiwan Application Serial No. 99115488, filed May 14, 2010, the subject matter of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] (1) Field of the Invention
[0003] The present invention relates to an error code correction method on a digital communication system, and more particularly to an error code correction method using the combination of error correction codes and block rearrangement to solve the packet loss issue.
[0004] (2) Description of the Prior Art
[0005] In the transmission of the digital signals, the distortion and errors generated by the timevarying decay and the Gaussian white noise are inevitable.
[0006] However, due to the help of the Error Correction Codes technology, digital signal transmission has a certain ability to recover signals from channel noise interference. And thus, error correction codes improve and enhance digital transmission reliability.
[0007] FIG. 1 shows a simplified digital signal transmission process. The original digital data stream signal M 1 is divided into segment blocks in the step 100 and then each block is added by a header in step 110 . An error correction coding is applied to each block in step 210 to become the signal c and the signal c is transmitted via the channel in step 500 .
[0008] A receiver receives the received signal R from the channel. As may be subject to noise interference or packet loss, the signal R can be expressed as R=C+e, where e is the noise. Afterwards, an error correction decoding is applied to the signal R in step 810 and then the head of to each block is removed in step 820 . Each block is recombined into a digital data stream M 2 . If the digital data stream M 2 is the same as the digital data stream M 1 , the signal transmission succeeds by the help of the Error Correction Codes technology in step 210 and 810 . If the digital data stream M 2 is not the same as the digital data stream M 1 , the Error Correction Codes technology in step 210 and 810 can not overcome the channel noise interference or packet loss during the transmission in step 500 .
[0009] In recent years, the error correction coding mainly is divided into two categories: linear block codes and nonlinear block codes. The ReedSolomon Code (RS code) and Low Density Parity Check Codes (LDPC code) are the best known and most widely used linear block codes.
[0010] RS code is proposed by Reed and Solomon in 1960 and an error correction code of a wide variety application with very good performance. It can not only correct the random errors but also correct the sudden Error (Burst error).
[0011] Low Density Parity Check Codes (LDPC codes for short) is proposed by Gallager in 1962. It is a method of iterative decoding. However, by the limited computer hardware performance at that time, the LDPC code was not taken serious attention by academia. Until 1993, when Berrou et al proposed Turbo codes, people accidently rediscovered LDPC codes have excellent performance and great value in implementation by the research of Turbo codes.
[0012] When the academic community reexamined the LDPC code, people found that if the code length is longer, the LDPC code can be closer to the Shannon Limit than the Turbo code. D. MacKay in 1996 proved that an iterative algorithm of LDPC codes can be with excellent performance approaching Shannon limit, or even irregular LDPC code can be with excellent performance approaching the Shannon limit with only the 0.0045 dB distance. So, following the Turbo code, LDPC codes attracts popular attention in channel coding theory recent years. Studies have shown that, by the iterative algorithm using the BP (Belief Propagation) algorithm, LDPC codes can be used with lower hardware complexity to achieve performance approaching Shannon limit.
[0013] On the research of RS codes and LDPC codes, a lot of works are related to error correction codes or even the research on the erasure codes. But their researches in the processing of packet loss are actually not many. We consider a packet loss situation by the help of FIG. 2 . FIG. 2 represents the segment blocks after the block segmentation step 100 of FIG. 1 . Each block length is f bits in the segment blocks. Therefore, if we lost a block, we lost continuous f bits. Thus, as long as the number of packet loss increases, the recovery of received digital signals by the error correction codes become serious difficult.
[0014] In order to enhance the recovery ability of error correction codes technology, many researches have used the cascade code (or concatenation code). The coding process combines two coding processes called inside and outside codes. But the inside and outside the codes uses different codes separately, for example the traditional DVB adopts the RS code as well as the convolution code. This approach certainly promoted the restoration effect, but their effect is still made little!
[0015] In 2006, Sarah J. Johnson in “ERASURE CORRECTING LDPC CODES FOR CHANNELS WITH PACKETS LOSSES” has proposed to solve the problem of packet loss. But the literature does not explain the design of the packet and Hperm. This is because the Hperm has its degree of difficulty truly in the design. In particular, for handling multiple packet loss problems, in order to ensure that one packet loss (random) can be resolved through other packets (i.e. uses Hperm), the difficulty of the Hperm design will be increased as lost packets number increases. So the implementation will face great challenges.
[0016] Therefore, in the noise and the packet loss environment, the research on how to transmit digital signals completely was still defective.
SUMMARY OF THE INVENTION
[0017] It is an object of the present invention to provide a method of handling packet loss and noise distortion using errorcorrecting codes and block rearrangement.
[0018] This invention proposed a method to reduce the packet loss impact on the recovery ability of error correction codes: applying the block rearrangement to segment blocks to make up the insufficient recovery ability of error correction codes technology.
[0019] The followings are another object of the present invention to provide a method of handling packet loss and noise distortion. This method comprises the steps of: (a) dividing the data stream signal into segment blocks; (b) applying the first error correction code coding on the segment blocks; (c) applying the block rearrangement on the segment blocks to break up the data of each segment blocks and spread the data into new formed segment blocks; (d) transmitting the new formed segment blocks via a channel with noise; (e) applying the received signals with reverse block rearrangement to restore the spread data; (f) applying the first error correction code decoding on the reverse rearrangement block and (g) combining these reverse rearrangement blocks back to the original data stream signal.
[0020] The followings are another object of the present invention to provide a method of handling packet loss and noise distortion. This method comprises the steps of: (a) dividing the data stream signal into segment blocks; (b) applying a first error correction code coding on the segment blocks; (c) applying the block rearrangement on the segment blocks to break up the data of each segment blocks and spread the data into new formed segment blocks; (d) applying a second error correction code coding on the segment blocks; (e) transmitting the segment blocks via a channel with noise; (f) applying the second error correction code decoding on the received blocks; (g) applying the received blocks with reverse block rearrangement to restore the spread data; (h) applying the first error correction code decoding on the block and (i) combining these reverse rearrangement blocks back to the original data stream signal. The above steps combine two error correction code technologies and a block rearrangement to solve the problem of packet loss and channel noise interference.
[0021] The features, objects, and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiment of this invention, with reference to the accompanying drawings:
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a flow chart showing conventional digital signal transmission processes with error code correction technology;
[0023] FIG. 2 is a graph showing the packet loss in a data stream;
[0024] FIG. 3 is a flow chart showing the encoding process in accordance with the first embodiment of the present invention;
[0025] FIG. 4 is a flow chart showing the decoding process in accordance with the first embodiment of the present invention;
[0026] FIG. 5 is a flow chart showing the encoding process in accordance with the second embodiment of the present invention;
[0027] FIG. 6 is a flow chart showing the decoding process in accordance with the second embodiment of the present invention;
[0028] FIG. 7 is a graph showing the block rearrangement in accordance with the present invention;
[0029] FIG. 8 is a graph showing the reverse block rearrangement in accordance with the present invention;
[0030] FIG. 9 is a graph showing the encoding process in accordance with the second embodiment of the present invention;
[0031] FIG. 10 is a graph showing the decoding process in accordance with the second embodiment of the present invention;
[0032] FIG. 11 is a flow chart showing the decoding process in accordance with the third embodiment of the present invention;
[0033] FIG. 12 is a graph illustrating the parity check matrix array in accordance with the third embodiment of the present invention;
[0034] FIG. 13 is a graph illustrating the parity check matrix array in accordance with the third embodiment of the present invention;
[0035] FIG. 14 is a diagram showing the packet loss versus transmission success rate; and
[0036] FIG. 15 is a diagram showing the packet loss versus bit error rate.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0037] FIG. 3 is a flow chart showing the encoding process in accordance with the first embodiment of the present invention. After the block segmentation of the original data stream M 1 in step 100 , the original data stream M 1 is divided into a plurality of fixedsize blocks. Then in the step 200 , a first error correction code coding is applied to each fixedsize block, and then a block rearrangement is applied to the first error correction code encoded blocks in step 300 . The purpose of the block rearrangement is to break up the data of each encoded blocks and spread the brokenup data into new formed segment blocks. After the block rearrangement, a header is added in each block to become signal C in step 110 and then the signal C is transmitted via the channel in step 500 . The signal C is composed of a plurality of blocks(pockets) with header.
[0038] The above first error correction code of FIG. 3 can be any kind of error correction codes, such as Turbo Code, RodSolomon code (RS code), and low density parity check code (LDPC code), BCH code, eIRA code, QCLDPC codes . . . and so on.
[0039] FIG. 4 is a flow chart showing the decoding process in accordance with the first embodiment of the present invention. After the transmission through the channel, the received signal R may be different from the signal C because of channel noise and packet loss. The header of each block(pocket) of the received signal R is removed in step 820 , and then a reverse block rearrangement is applied to the blocks to restore the spread data from every blocks in step 700 . Then the first error correction code decoding is applied to each block in step 800 and the blocks are combined to become data M 2 in step 900 . If the data stream M 2 of FIG. 4 is the same as the data stream M 1 of FIG. 3 , the coding and decoding processes can overcome the channel noise and packet loss issues during channel transmission.
[0040] FIG. 5 is a flow chart showing the encoding process in accordance with the second embodiment of the present invention. After the block segmentation of the original data stream M 1 in step 100 , the original data stream M 1 is divided into a plurality of fixedsize blocks. Then in the step 200 , a first error correction code coding is applied to each fixedsize block, and then a block rearrangement is applied to the first error correction code encoded blocks in step 300 . The purpose of the block rearrangement is to break up the data of each encoded blocks and spread the brokenup data into new formed segment blocks. After the block rearrangement, a header is added in each block in step 110 and a second error correction code coding is applied to each block to become signal C in step 400 , and then the signal C is transmitted via the channel in step 500 . The signal C is composed of a plurality of blocks(pockets) with headers.
[0041] The above first and second error correction code of FIG. 5 can be any kind of error correction codes, such as Turbo Code, RodSolomon code (RS code), and low density parity check code (LDPC code), BCH code, eIRA code, QCLDPC codes . . . and so on.
[0042] FIG. 6 is a flow chart showing the decoding process in accordance with the second embodiment of the present invention. After the transmission through the channel, the received signal R may be different from the signal C because of channel noise and packet loss. A second error correction code decoding is applied to each block(pocket) of the received signal R in step 600 and the header of each block(pocket) of the received signal R is removed in step 820 , and then a reverse block rearrangement is applied to the blocks to restore the spread data from every blocks in step 700 . Then the first error correction code decoding is applied to each block in step 800 and the blocks are combined to become data M 2 in step 900 . If the data M 2 of FIG. 6 is the same as the data stream M 1 of FIG. 5 , the coding and decoding processes can overcome the channel noise and packet loss issues during channel transmission.
[0043] FIG. 7 illustrates the step 300 of FIG. 3 and FIG. 5 , i.e. the block rearrangement of the present invention. First, we define the following symbols: Dp is the Dth code word (or bit) of the Pth block and the Dp can be binary (binary) or nonbinary (nonbinary). For example, 1 2 represents 1st code word (or bit) of the second block. The upper row 310 represents the blocks before block rearrangement, while the lower row 320 represents the blocks after the block rearrangement. The 1st code word (or bit) of each block in the upper row 310 are placed to the 1st block of the lower row 320 in sequence; Similarly, then 2nd code word (or bit) of each block in the upper row 310 are placed to the 2nd block of the lower row 320 in sequence, . . . , and so on, thus we can complete the block rearrangement. If the blocks of the upper row 310 contains P blocks and each block contains D code words(or bits), then the lower row 320 after rearrangement is a row with D blocks and each block contain P code word (or bits).
[0044] FIG. 8 is the step 700 of FIG. 4 and FIG. 6 , i.e. the reverse block rearrangement of the present invention. The upper row 710 represents the blocks before reverse block rearrangement, while the lower row 720 represents the blocks after the reverse block rearrangement and we assume that the second block were lost during channel transmission. The code words (or bits) of the first block in the upper row 710 are placed to the first code word (or bit) of every blocks in the lower row 720 one by one; Similarly, The code words (or bits) of the 3rd block in the upper row 710 are placed to the 3rd code word (or bit) of every blocks in the lower row 720 one by one, . . . , and so on, thus we can complete the reverse block rearrangement. The 2nd code word (or bit) of each block in the lower row 720 is unknown because of the lost of the second block(or pocket). The unknown word (or bit) of each block from the lost pocket can be restored by the error code correction technology or the erase code correction technology.
[0045] From FIG. 3 to FIG. 8 , we can see that the present invention can transform the pocket lost issue into a erased code issue by the help of the block rearrangement step 300 and reverse block rearrangement step 700 . And then the error code technology or erased code technology can be applied to restore the lost data.
[0046] FIG. 9 illustrates the encoding process in accordance with the second embodiment of the present invention, i.e. from step 100 to step 400 of FIG. 5 . Please also refer to FIG. 5 , the 1st row 111 of FIG. 9 represents the blocks after block segmentation. The first error correction code encodes each block of the row 111 to become each block of 2nd row 211 and the check bits are added to the end of each block of the 2nd row 211 . The block rearrangement is applied to the 2nd row 211 to become the 3rd row 311 . Each block of the 3rd row 311 is added by a header to become the 4th row 112 . The second error correction code encodes each block of the row 112 to become each block of 5th row 411 and the check bits are added to the end of each block of the 5th row 411 . Then the 5th row 411 can be transmitted through the channel.
[0047] FIG. 10 illustrates the decoding process in accordance with the second embodiment of the present invention, i.e. from step 600 to step 800 of FIG. 6 . Please also refer to FIG. 6 , the 1st row 511 of FIG. 10 represents the received blocks(pockets). The second error correction code decodes each block of the row 511 to become each block of 2nd row 611 and the check bits are removed from the end of each block of the 2nd row 611 . The header of each block of the 2nd row 611 is removed to become the 3rd row 821 . The reverse block rearrangement is applied to the 3rd row 821 to become the 4th row 711 . The first error correction code decodes each block of the 4th row 711 to become each block of 5th row 811 and the check bits are removed from the end of each block of the 5th row 811 . Then the 5th row 811 are combined into digital data M 2 .
[0048] The third embodiment of the present invention adopts RS code as the first error correction code and LDPC code as the second error correction code in FIG. 5 . We describe the RS coding and decoding procedures of the third embodiment as follows:
[0049] In the RS code coding procedure, if the data code word (i.e. the message) length is k, the encoded code word length is n, t is the maximum number of errors corrected and k satisfies n−k=2t. The generating polynomial g(x) is:
[0000]
g
(
x
)
=
∏
i
=
b
b
+
2
t
-
1
(
x
-
α
i
)
[0000] The α is the element of a finite field GF (2 m ). To generate the elements of GF (2 m ) requires a primitive polynomial ρ (x), and a is the root of ρ (x).
[0050] With the generating polynomial g (x), we can encode the message as follows: First of all, the original message will be transformed into a polynomial m (x). The polynomial m (x) is encoded to become a polynomial C (x), wherein C (x) is:
[0000] C ( x )= x n-k ·m ( x )+ r ( x )
[0000] The γ(x) is the remainder of the polynomial x n-k ·m(x) divided by polynomial g(x).
[0051] FIG. 11 is a flow chart showing the RS decoding process in accordance with the third embodiment of the present invention. The received signal is the polynomial r (x) in step 822 and the polynomial r (x) is:
[0000]
r
(
x
)
=
r
n
-
1
x
n
-
1
+
r
n
-
1
x
n
-
2
+
…
+
r
1
x
+
r
0
∘
=
∑
i
=
0
n
-
1
r
i
x
i
[0000] We assume that receiving polynomial r (x)=C (x)+e (x) and e (x) is the error polynomial. The adjoin(or symptom) polynomial of receiving polynomial r (x) is S(x) and S(x) is:
[0000] S=r·H T =( S 1 , S 2 , . . . , S n )
[0000] and the paritycheck matrix H is,
[0000]
H
=
[
1
α
α
2
…
α
n
-
1
1
α
2
(
α
2
)
2
…
(
α
2
)
n
-
1
1
α
3
(
α
3
)
2
…
(
α
3
)
n
-
1
⋮
⋮
⋮
⋱
⋮
1
α
2
t
(
α
2
t
)
2
…
(
α
2
t
)
n
-
1
]
[0000] The adjoin polynomial S(x) is:
[0000]
S
i
=
r
(
α
i
)
=
r
n
-
1
α
(
n
-
1
)
i
+
r
n
-
2
α
(
n
-
2
)
i
+
…
+
r
1
α
i
+
r
0
i
.
e
.
S
i
=
∑
j
=
0
n
-
1
r
j
(
α
i
)
j
[0000] Where in i=1, 2, . . . , 2t∘
And then
[0000] r ( x )= c ( x )+ e ( x )
[0000] r (α i )= c (α i )+ e (α i )
[0000] S i =c (α i )+ e (α i )
[0052] In the decision step 832 of FIG. 11 , if all the S i (x)s are equal to 0, the receiving polynomial r(x) is the same as polynomial C(x) and the receiving signal is received without distortion or noise. Thus the RS decoding process is finished. If any Si (x) are not 0, then go to the next step 842 .
[0053] Since c (α)=0, so we can get r (α i )=e (α i ) and we assume that there are r numbers of errors of e (x) in the
[0000] x j 1 , x j 2 , . . . , x j r
[0000] i.e.
[0000] e ( x )= x j 1 +x j 2 + . . . +x j r
[0000] Wherein 0≦j 1 <j 2 < . . . <j r ∘ So we can get the following S i :
[0000]
S
1
=
α
j
1
+
α
j
2
+
…
+
α
j
r
S
2
=
(
α
j
1
)
2
+
(
α
j
2
)
2
+
…
+
(
α
j
r
)
2
⋮
S
2
t
=
(
α
j
1
)
2
t
+
(
α
j
2
)
2
t
+
…
+
(
α
j
r
)
2
t
[0000] We simplify the above formula as follows:
[0000]
S
1
=
β
1
+
β
2
+
…
+
β
r
S
2
=
β
1
2
+
β
2
2
+
…
+
β
r
2
⋮
S
2
t
=
(
β
1
)
2
t
+
(
β
2
)
2
t
+
…
+
(
β
r
)
2
t
[0000] As shown in step 842 , we can define the error location polynomial σ (x) and its roots is the inverse of the error location. From the above formula the roots can be β 1 −1 , β 2 −1 , . . . , β r −1 . Thus we can write σ(x) as follows:
[0000]
σ
(
x
)
=
(
1
+
β
1
x
)
(
1
+
β
2
x
)
…
(
1
+
β
r
x
)
=
σ
0
+
σ
1
x
+
σ
2
x
2
+
…
+
σ
r
x
r
[0000] From the roots and coefficients of the above equation, we can get the followings:
[0000]
σ
0
=
1
σ
1
=
β
1
+
β
2
+
…
+
β
r
σ
2
=
β
1
β
2
+
β
2
β
3
+
…
+
β
r
-
1
β
r
⋮
σ
r
=
β
1
β
2
…
β
r
[0000] and
[0000] σ(β l −1 )=σ 0 +σ 1 β l −1 +σ 2 β l −2 + . . . +σ r β l −r =0
[0054] Therefore, by solving σ (x)=0, we can get the error locations. According to Newton's identities, we can establish the linear relationship between σ i and S j . The above equations can be reconstructed to be t numbers of equations with t numbers of unknown. These equations can be expressed as a matrix form of a linear equation:
[0000]
[
S
1
S
2
…
S
t
S
2
S
3
…
S
t
+
1
⋮
⋮
⋱
⋮
S
t
S
t
+
1
…
S
2
t
-
1
]
[
σ
t
S
t
-
1
⋮
σ
1
]
=
[
S
t
+
1
S
t
+
2
⋮
S
2
t
]
[0055] Several ways of solving the above matrix equations: PGZ algorithm (PetersonGorensteinZierler Algorithm), BM algorithm (BerlekampMassey Algorithm), and the Euclidean algorithm (Euclidean Algorithm). We describe the BM algorithm in the followings:
[0056] BM algorithm is a iterative method to calculate the associated polynomial S j =r(α j ), the first step is to find the smallest power polynomial σ 1 (x), so it satisfies the first equation:
[0000] S 1 +σ 1 (1) =0
[0000] The next step is to substituted σ (1) (x) into the following formula:
[0000] S 2 +σ 1 (1) S 1 +2σ 2 (1) =0
[0000] If the substitution satisfies the above equation, we let
[0000] σ (2) ( x )=σ (1) ( x )
[0000] Otherwise, we amended σ(x) as follows:
[0000] σ (n+1) ( x )=σ (n) ( x )− d n d m −1 x (n−m) σ (n) ( x )
Wherein
[0057] d n =S n+1 +σ 1 (n) S n +σ 2 (n) S n−1 + . . . +σ l n (n) S n+1−l n
[0000] And the above iteration stop when i≧l i+1 +t d −1 or i=2t d −1.
[0058] As shown in step 852 , in finding the roots of error location polynomial, no effective algorithm can be found currently and the only way is to substitute the values into the error location polynomial by Chien search.
[0059] As shown in step 862 , after using of Forney algorithm, the formula is as follows:
[0000]
e
j
l
=
(
α
j
l
)
2
-
b
·
Λ
(
α
-
j
l
)
σ
′
(
α
-
j
j
)
[0000] Wherein (x)=σ(x)·(x) mod X 2.td+1 and td is the numbers of corrected code words, and
[0000] S ( x )=1 +S 1 x+S 2 x 2 + . . . +S 2·t d +1 x 2·t d .
[0060] Thus, as shown in step 872 , the receiver can get the original code word C (x)=r (x)+e (x), where r (x) is the received signal, e (x) is the error polynomial we derived.
[0061] As shown in FIG. 8 , if the pocket loss occurs, the RS decoding procedure becomes the erase code correction. In order to decode the erase code correction of the RS code, we adopt the following erase position polynomial
[0000]
τ
(
x
)
=
∏
l
=
1
μ
(
1
+
y
i
l
x
)
[0000] With the modified Forney modifier
[0000] T ( x )= S ( x )·τ( x )+1 mod x 2t d + 1 .
[0000] Because the Forney modifier is modified as above, we redefine the d i as follows:
[0000]
d
i
=
T
i
+
μ
+
1
+
∑
j
=
1
l
i
σ
j
(
i
)
T
i
+
μ
+
1
-
j
[0000] The d 0 is T i+μ+1 and the iteration stop when i≧l i+1 +t d −1−μ/2.
[0062] When the iteration meets the iteration stop condition, the algorithm was stop and we get a σ(x). With the σ(x), we can calculate the value correction polynomial ω (x):
[0000] ω( x )=[1 +T ( x )]σ( x ) mod x 2t d +1 .
[0000] And the position correction polynomial ψ(x):
[0000] φ( x )=τ( x )σ( x )
[0000] With the modified Forney algorithm, we can calculate the following equation for the error value:
[0000]
e
j
l
=
(
α
j
l
)
2
-
b
ω
(
α
-
j
l
)
φ
′
(
α
-
j
l
)
[0000] Wherein 1≦l≦v and the erased value can be derived from
[0000]
f
i
l
=
(
α
i
l
)
2
-
b
ω
(
α
-
i
l
)
φ
′
(
α
-
i
l
)
[0000] So we can get C(x) by C(x)=R(x)+e(x)+f(x) and the decoding procedure end.
[0063] In the followings, we describe the LDPC code implementation of the third embodiment of the present invention. The LDPC code is a linear block code, so it is encoded like other linear block code. The parity check matrix H of the LDPC code is a sparse matrix and will correspond to a generator matrix G satisfying the following equation:
[0000] G·H T =0.
[0064] And the coding is done by c=m·G, wherein the m is the message to be transmitted.
[0000] A lot of design for the parity check matrix have been presented. A common design, such as Gallager codes are as follows:
[0000]
H
=
[
H
0
H
0
∏
1
⋮
H
0
∏
ω
c
-
1
]
H
0
=
[
11
…
1
w
r
00
…
0
w
r
…
00
…
0
w
r
00
…
0
11
…
1
…
00
…
0
⋮
⋮
⋱
⋮
00
…
0
00
…
0
…
11
…
1
]
[0000] Wherein π i , i=1 . . . w C −1 means the permutation of H 0 .
In the implementation, since the parity check matrix is sparse, we need only produce a 1 position so that we can create the whole parity check matrix. Taking a 15 by 20 parity check matrix H for example: we use an array and put the number from 0 to 19 into the array, these 20 values represent the numerical line, in other words, a value of 9 would represent the 9th row. It is shown in FIG. 12 .
The next step is to establish H 0 :
[0000]
H
0
=
[
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
]
[0000] The establish of H 0 is to take 4 data out of the array of FIG. 12 at a time and put into the H 0 in order.
In order to avoid the short ring with length 4, we have to permute H0 as follows:
[0000]
H
1
=
[
0
17
14
11
4
1
18
15
8
5
2
19
12
9
6
3
16
13
10
7
]
[0000] By comparing H1 with H0, we can know that the first column of H1 is the same as the first column of H0. Every data in the second row of H1 is moved to the next column and the fifth column of the second row of H1 is moved to the first column. Every data in the third row of H1 is moved to the next two columns, , . . . , and so on. Therefore, we can get the following relationship about H1:
If we assume
[0000] H 0 =( h ij ) 1≦i≦5,1≦j≦4
[0000] Then
[0000] H 1 =( h ij ′)
[0000] and
[0000]
h
ij
′=h
kj
[0000] Wherein k=(i+j) mod 5, so we can get H1. We can establish H2 in a similar way.
H2 is not established from H0 but H1.
[0000] H 2 =( h ij ″)
[0000] and
[0000] h ij ″=h kj ′
[0000] Wherein k=(i+j) mod 5 and the H2 is
[0000]
H
2
=
[
16
9
2
15
0
13
6
19
4
17
10
3
8
1
14
7
12
5
18
11
]
[0000] Thus, a 15 by 20 parity check matrix H can be established as follows:
[0000]
H
=
[
H
0
H
1
H
2
]
[0065] In order to enhance the ability for decoding and encoding, we need to create a random parity check matrix structure, we can make a little amendment to the above method. We reconstruct the array of FIG. 12 to be the array of FIG. 13 . The values between 0 to 19 after a random permutation is replaced in the array, then we can establish a parity check matrix H like Gallager code.
[0066] The followings are the LDPC decoding procedure.
[0000] LDPC codes decoding algorithm adopts primarily the method of message passing algorithm, so the decoding algorithm is as follows:
(0)initial:
[0000]
q
ij
(
0
)
=
1
-
p
i
=
P
r
(
x
i
=
+
1
/
y
i
)
=
1
1
+
2
y
i
/
σ
2
q
ij
(
1
)
=
p
i
=
P
r
(
x
i
=
-
1
/
y
i
)
=
1
1
+
2
y
i
/
σ
2
r
ji
(
0
)
=
1
2
+
1
2
∏
i
′
∈
R
j
\
i
(
1
-
2
q
i
′
j
(
1
)
)
r
ji
(
0
)
=
1
-
r
ji
(
0
)
(
1
)
q
ij
(
0
)
=
K
ij
(
1
-
p
i
)
∏
j
′
∈
C
i
\
j
r
j
′
i
(
0
)
q
ij
(
1
)
=
K
ij
p
i
∏
j
′
∈
C
i
\
j
r
j
′
i
(
1
)
(
2
)
[0000] Wherein Kij is a constant to make qij(0)+qij(1)=0.
(3) for any i,
[0000]
Q
i
(
0
)
=
K
i
(
1
-
p
i
)
∏
j
∈
Ci
r
ji
(
0
)
Q
i
(
1
)
=
K
i
p
i
∏
j
∈
Ci
r
ji
(
1
)
[0000] Wherein Ki is a constant to make Qi(0)+Qi(1)=1.
[0000]
·
∀
i
C
~
=
{
1
if
Q
i
(
1
)
>
0.5
0
else
·
if
C
_
^
H
T
=
0
_
(
4
)
[0000] or the iteration number is equal to the maximum iteration number, then stop, otherwise return to (1).
[0067] FIG. 14 is a diagram showing the packet loss v.s. transmission success probability for the first embodiment of the present invention. The comparison is made between RS coding with block rearrangement and RS coding without block rearrangement. With RS coding and block rearrangement, 15 RS(15,7,9) packets are used for simulation. Each code word contains four characters and the overall data are 900 characters. Without block rearrangement, a RS (127,63,65) packet is used for simulation. Each code word contains 7 characters and the overall data are 899 characters. The pocket without block rearrangement is then divided into 15 packets for transmission. The success of the packet transmission does not allow any one bit error. The channel is without noise interference but with packets lost interference. The simulation results show that without block rearrangement, a packet loss makes the transmission fail; but with block rearrangement, we can successfully restore the data on condition that 4 pockets are lost.
[0068] FIG. 15 is a diagram showing the packet loss v.s. bit error rate for the second embodiment of the present invention. The first error correction code adopts RS code and the second error correction code adopts LDPC code. The channel is with noise interference and packets lost interference. We simulate for the 1000 times transmission and each transmission transmits 15 fixed size packets.
[0069] We use the RS(15,8,7) coding in the simulation. In the LDPC codes encoding, we adopted a code rate of 1/2. we assume that the channel with the packet loss interference and the noise interference. We use simulated Gaussian noise with variance from 0.1 to 0.3.
[0070] In FIG. 15 , RN represents block rearrangement and NonN represents no block rearrangement. The RS(127,63,65) code is used without block rearrangement. The simulation shows that the EBR is lower with the block rearrangement.
[0071] Although the present invention and its advantages have been described in detail, as well as some variations over the disclosed embodiments, it should be understood that various other switches, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. | A method of handling packet loss uses errorcorrecting codes and block rearrangement. This method divides the original data stream into data blocks, then codes the blocks by errorcorrecting codes. After coding the blocks, rearranges the coding blocks for spreading original data into new blocks and then transmitting the new blocks.
After receiving the transmitted blocks, reverserearrangs the received blocks and decode the blocks. Combine the decoded blocks into original data stream in the end. | 97,387 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the priority of U.S. Provisional Application No. 60/704,839 filed Aug. 2, 2005 for a “Wearable Electronic Scorekeeping Device”.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention is a wrist-wearable scorekeeping device, such as worn by a participant in racquet court games such as tennis, racquetball, and table tennis, and which includes a total of five settable buttons for navigating through mode/menus, displays and score entry functions.
[0004] 2. Description of the Prior Art
[0005] The prior art is well documented with examples of tennis and other portable type scorekeeping devices for assisting a player in keeping a correct score during game play. A first example from the prior art is set forth in U.S. Pat. No. 6,634,548, to Bowman, and which teaches a flexible strap removably attached to a casing, the casing in turn incorporating a circuit chip and a battery. The circuit chip is activated by one or more of four activation switches, these causing information (activities) to be displayed in one or more of four separate displays. Additionally, two additional activation switches are used to either turn the unit on/off and/or to reset one or more of the displays.
[0006] Another example of a personal tennis score keeper is disclosed in U.S. Pat. No. 5,489,122, to Pittner, and which teaches a strip of sheet material having an upper surface and a lower surface, the upper surface bearing squares arranged in a linear array and forming three columns. A first column bears indicia indicating the number of games won by a player, another indicates the number of games won by an opposing player, and the remaining bearing indicia for indicating a score of each player during a game. A plurality of score markers are slidably secured to the strip in a juxtaposed slidable relation with respect to a column for marking a score.
[0007] U.S. Pat. No. 3,777,699, issued to Pfleger, teaches a scoring device for tennis which accumulates and indicates the scoring for the game which is divided into and known as point score and game score. Scoring in tennis requires both an additive mode of operation for accumulating point score as well as game score, and a subtractive mode for point scoring under certain tie score conditions. The scoring device therefore comprises an input member and a totalize register for sequentially adding the point score until sufficient points have been accumulated to win the game. In advancing the point score register into the game winning indication the game totalizing register automatically advances to the next indication. The point score register is capable of the additive and the subtractive movements by selective movement of the input member. U.S. Pat. No. 4,331,098, issued to Rubano, teaches a tennis score keeper incorporating a small sized device for keeping score of a tennis match and which can be conveniently carried around on either a player's wrist or mounted on a racket. The device includes a frame on which is imprinted a row of point scores and a row of game scores along which arrows for each player are slidable.
[0008] Finally, U.S. Pat. No. 6,210,296, issued to Gabriel, teaches a portable tennis scorekeeper device with a body attachable to an article of apparel or insertable within a pocket thereof worn by a tennis player and including a scoreboard applied to a side of the portable body. The scoreboard includes a middle region and a pair of opposite side regions. The middle region includes a first portion having a plurality of numbers and letters associated with points scored in a game of a tennis match. A pair of tracks extend along opposite sides of the first portion, second and third portions each being disposed on a side of one of the tracks opposite from the first portion and having a plurality of numbers associated with points scored in a tiebreaker of the tennis match. A pair of markers are each mounted to and for undergoing movement along one of the tracks and are alignable with the numbers and letters of the first, second and third portions.
[0009] The side regions of the scorecard are each disposed on a side of one of the scorecard and third portions opposite from the tracks. Each side region includes a grid formed by a side axis, an end axis extending generally orthogonally to the side axis, a plurality of boxes arranged in rows and columns and aligned with one another adjacent to the side and end axes, a plurality of numbers associated with the games won in one or more sets of the tennis match being disposed numerically along the side axis and a plurality of numbers associated with sets of the match disposed numerically along the end axis. A plurality of markers are each mounted to and movable along the grid in generally orthogonal directions and positionable on one of the boxes of the grid and alignable with the numbers along each of the side and end axes of the grid.
SUMMARY OF THE PRESENT INVENTION
[0010] The present invention discloses an electronic wearable scorekeeping device which is an improvement over prior art designs in that it provides a five button arrangement for game play and display functions. The device is further adaptable to a number of different racquet type sports and, in one preferred tennis variant, includes features such as scorekeeping, identifying game and set tally, as well as unforced errors.
[0011] A timekeeping mode is also employed and provides the ability to convert the wearable device between scorekeeping and watch functions. Additional features enable the present device to convert to scorekeeping in other related racquet sports, including badminton, racquetball, table tennis and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Reference will now be made to the attached drawings, when read in combination with the following detailed description, wherein like reference numerals refer to like parts throughout the several views, and in which:
[0013] FIG. 1 is an illustration of an electronic scorekeeping device according to the present invention for use with tennis and in particular showing the arrangement of the five pushbutton arrangement for switching between play, time, display modes;
[0014] FIG. 2 is a succeeding illustration of the electronic scorekeeping device and showing the display mode indicated;
[0015] FIG. 3 is a tabular illustration of a series of variable names and associated purpose/functions for the scorekeeping device according to the present invention;
[0016] FIG. 4 is a first flow schematic illustration of an initial play mode associated with the scorekeeping device of FIG. 1 ;
[0017] FIG. 5 is a succeeding tally score flow illustration associated with the present invention;
[0018] FIG. 6 is a flow schematic of a next game protocol;
[0019] FIG. 7 illustrates a flow schematic of a next set game play protocol;
[0020] FIG. 8 is a flow schematic of a normal score tally according to the present invention;
[0021] FIG. 9 is a flow schematic of a protocol associated with a tiebreaker scoring situation;
[0022] FIG. 10 is a flow schematic of a display score mode according to the present invention;
[0023] FIG. 11 is a clear score schematic according to the present invention;
[0024] FIG. 12 is a further succeeding display mode schematic; and
[0025] FIG. 13 is a final schematic illustration of the electronic scorekeeping device according to the present invention and which provides a selectable mode for different racquet sports including racquetball, badminton, etc.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] Referring now to FIG. 1 , a wrist-wearable electronic scorekeeping device is illustrated at 10 according to a preferred embodiment of the present invention. As indicated previously, the scorekeeping device is typically worn by a participant of a court-related sport, and the device 10 represents a first embodiment directed to the game of tennis, it being understood that the wearable electronic scorekeeping device is equally applicable to other racquet sports such as racquetball, badminton, table tennis and the like.
[0027] In a preferred variant, the device 10 is worn upon a user's wrist (not shown). A strap or optional belt clip (also not shown) may also be provided for the wearability of the device, such as upon some secure location of the user, and such as again the belt or wrist.
[0028] Referring again to FIG. 1 , the tennis scorekeeping device 10 includes a durable body exhibiting an LCD display face 12 and upon which are noted a series of indicia indications (such as in LCD format display) for indicating game play features associated with the present design. It is also understood that other means of illuminating display, such as including LED, phosphorescent or the like may also incorporated into the design.
[0029] A series of pushbuttons are illustrated (in one non-limiting variant as illustrated) at various locations around a side periphery of the body and include first player score toggle (or A button) 14 (exhibited along one side of the device), and corresponding to second player toggle (or B button) 16 exhibited along an opposite side. Each of these toggle buttons are considered “universal” buttons and will allow the wearer to scroll through scores in one direction only to simplify. Each of these buttons further include a slip-resistant surface and enable the participant/player to toggle (up or through) to display a current score.
[0030] A third display mode pushbutton is illustrated at 18 (see along lower right-hand side of the body), along with a fourth button 20 (lower left-hand side) is provided for viewing previously scored games and/or sets and matches. In play mode, fourth button 20 is provided for inputting unforced errors and clearing individual scores. Finally, a time mode button, see at 22 along right-hand side is provided for providing associated timer functions to the present design, such contemplated to include alternating between watch (i.e. timekeeping) and scoring functions through the pressing of a single button.
[0031] As will be subsequently described, the two main modes for scorekeeping are play mode and display mode. In play mode, a player can indicate which team (or individual player) has earned a point, and such as by depressing either button 14 or 16 once. Additionally, the user can increase entry of unforced errors (see again button 20 ) and can further clear an individual score (hold down button 20 for one second) or can clear all scores (hold button 20 for three or more seconds). Pressing button 18 will take the player to the display mode.
[0032] In the display mode, see illustration 24 in FIG. 2 , a user can navigate through current matches (whether or not completed), and to select fourth button to view individual games or sets. In this mode, first button 14 increments which game/set to display, whereas second button 16 decreases which game/set is being displayed. Third button 18 reverts to play mode (back to a previous game) and fifth button 22 to time mode, as previously described. In the illustration 24 of FIG. 2 , the device is illustrated in display mode according to the game of tennis (see indication 26 for “T”), game 2 (at 28 ) set 2 (at 30 ) and with a score of 30-50 (at 32 ), thus indicating a win by the “B” team with no unforced errors (at 34 for designation “UFE”). In contrast, the play mode of FIG. 1 is referenced, see on display face 12 at 36 , as indicated by tennis mode (again at 26 ), game 4 (at 28 ′), set 1 (at 30 ′), score (30-15), indicating a lead by team/player “A” and with one unforced error (at 34 ′).
[0033] Referring now to FIG. 3 , a tabular illustration is shown at 38 of a series of variable names and associated purpose/functions for the scorekeeping device according to the present invention. The purpose of FIG. 3 is to illustrate, in tabular form, a sequential listing of variables utilized to maintain scores and flags of functions as will be described in more detail with reference to the following flowchart illustrations.
[0034] FIG. 4 illustrates a first flow schematic illustration of an initial play mode 40 associated with the scorekeeping device of FIG. 1 . According to the flow sequence illustrated, a user presses button 1 (see again at 14 in FIGS. 1 and 2 ) and which commences by the user pressing either button (at 42 ) or button 2 (at 44 ) to determine the awarding of a point, to player A at 46 or to player B at 48 .
[0035] Progressing to step 50 , a tally score indication queries whether either party/team has successfully achieved a score of 100. If no, game play continues along step 52 . If yes, and in the instance of an A score of 100 (as in step 56 ), a further instruct is made to increase a number of A games (at 58 ). If no, a further step 60 instructs to increase B game. At step 62 , a next game is selected and succeeding step 64 queries if the match is completed. If so, match score 66 is indicated at 66 and the protocol returns to display mode at 68 .
[0036] If the query to pressing button 2 (at 16 ) is no (referencing back to step 44 ) succeeding step 70 queries whether to depress button 3 (see again also 18 in FIG. 1 ). If yes, display mode is illustrated at 72 . If no, a query whether to depress button 5 (at 22 ) is given at 74 . If yes, the display proceeds to time mode 76 and, if no, to querying whether to depress button 4 (at 20 ) at step 78 .
[0037] If the answer to query 78 is yes, a further query asks whether to depress button 4 ( 20 ) for one section (at 80 and thereby to clear a given player/team score). If yes, a further query asks whether to hold button 4 for three plus seconds (at step 82 ). If no (at 84 ) all scores (A, B and UFE) are at 0 (at step 84 ) and, if yes, all scores are cleared at step 86 . If the answer to query 80 is no, step 88 instructs an increase of A error (again unforced error or UFE as referenced at 34 in FIG. 1 ) to eventual score display 90 . Finally, and if the answer to query 78 is no (at 92 ), the protocol returns to initial play mode 40 .
[0038] Referring now to FIG. 5 is a succeeding tally score flow illustration associated with the present invention, and in particular its ability to adapt to multiple game type variants, is shown at 94 and includes a first query, at 96 , as to whether the game selection is tennis. If yes, at 98 , a tiebreaker query is made and, if yes, a tiebreaker score is indicated at 100 . If no, a normal tennis score is indicated at 102 . Irrespective of selection 100 or 102 , a display tennis score is referenced at 104 and the protocol ends at 106 . If the query to 96 is no, a further query is posited at 108 as to the selection of another type of game, e.g. racquetball, with a remaining tally protocol being repeated as to steps 98 - 106 .
[0039] As is now shown in FIG. 6 , is a flow schematic of a next game protocol indicated at 110 queries, at step 112 , whether tennis is the selected game and, if yes, at step 114 instructs to record game statistics. At step 116 , A player score is queried (e.g. as shown as 100) and, if yes, at step 118 the scores are zeroed out. At succeeding step 120 , a number of A games (e.g. 7 ) is queried and, if yes, an increase of A sets is indicated at 122 ., succeeding which is the device issuing an audible sound (e.g. beep and which is understood to be incorporated into its hardware design) succeeding which a next set indication is shown at 126 and end step 128 .
[0040] If the answer to query 120 is no, query 130 posits whether a given A and B game situation (e.g. Agame=6 AND Bgame<=4) exists. If yes, the protocol proceeds to step 122 previously described and, if no, a further query is posited whether both A and B games equal a given number (at 132 and shown as 6 games apiece). If yes, a tiebreaker indication is shown at 134 and, following a beep-beep audible alarm (see further at 136 ), the protocol proceeds to end step 138 .
[0041] If the query to 116 is no, step 140 instructs both A and B scores to zero out, following which, at step 142 , a query is made as to whether B team/player is referenced to have played a certain number of games (e.g. such as 7 and corresponding to Agame=7 query in step 120 ). If yes, a number of team B sets (Bset) is increased at 144 . If no, query 146 reciprocates that shown at 130 and queries whether Bgame=6 AND Agame<=4). If yes, Bset is increased again at 144 and, if no, the protocol proceeds to step 132 previously described.
[0042] FIG. 7 illustrates a flow schematic of a next set game play protocol, at 148 , and proceeds to a record set stats instruct at 150 . Succeeding steps include an instruct to zero out both A and B games to zero (at 152 ) and to subsequently query, at step 154 , if both an Aset or a Bset equals a specified number (e.g. 2). If yes, match completed indication is given at 156 and, if no (at 158 ), query 154 proceeds directly to beep indication 160 and end protocol step 162 .
[0043] FIG. 8 is a flow schematic of a normal score 164 tally according to the present invention, such as again for tennis play, and queries at 166 if a point is to be awarded to player A. If yes, at 168 , an Ascore=0 is queried. If yes, an Ascore may be increased, such as to equal 15 (at 170 ). If no to 168 , a further query asks if Ascore is already at 15 (at 172 ). If yes, Ascore is queried at 30 (at 174 ) and, if no, Ascore is queried whether at 30 (at 176 ). If yes, at 178 , Ascore is advanced to 40 and, if no, a combined A and B score of 40 apiece is queried, at 180 , whether as being 40 apiece. If yes, Ascore is advanced to 50 (at 182 ) and, if no, queried further at 184 whether an Ascore=40 and a Bscore=50. If yes to 184 , Bscore is advanced to 40 and, if no, Ascore to 100 (at 188 ).
[0044] The protocol of steps 168 - 188 is repeated in reciprocal as shown in FIG. 8 for query 190 as to whether Bscore=0 (this reciprocating previously described query 168 ). Succeeding query steps 192 - 210 are referenced in downwardly progressing fashion along the left side column of the flowchart of FIG. 8 and correspond with each of previously described steps 170 - 188 . The protocol of FIG. 8 concludes with end step 212 , progressing from either described step 188 or 210 .
[0045] FIG. 9 is a flow schematic of a protocol associated with a tiebreaker scoring situation 214 and queries, at 216 , whether to increase Ascore (at 218 ). If no, at step 220 , a query is made whether to advance an Ascore, such as to >=7 AND Ascore-Bscore>=2). If yes, at 222 , Ascore is advanced to 100.
[0046] Steps 224 , 226 and 228 correspond reciprocally to steps 218 , 220 and 222 , as to increasing Bscore, and if yes to either query 220 or 226 , either the A or B score is advanced to 100 and end step 230 referenced. If no to either 220 or 226 , the protocol proceeds directly to end step 230 .
[0047] FIG. 10 is a display score flow schematic 232 and queries, at 234 , whether A and B score both equal 40. If yes, at step 236 , “deuce” indication is made and, if no, a query is made at 238 whether Ascore=40 and Bscore=50. If yes “Adou” indication is made at 240 and, if no, further query 242 asks is Ascore=50 and Bscore=40. If yes, at 244 “Adin” is indicated and, if no, Ascore=100 is further queried at 246 . If yes, at 248 , “Awin” (A team wins) is indicated at 248 and, if no, Bscore=100 is queried at 250 . If yes, Bwin (B team wins) is indicated at 252 .
[0048] If no to query 250 (or if yes to any preceding indications 236 , 240 , 244 , 248 and 252 ), further Ascore:Bscore (e.g. the present team scores where either team has some point total under 100, or any other preset total point amount constituting a win) is referenced at 254 . Following that, an unforced errors (UFE) indication is given at 256 and proceeds to end protocol step 258 .
[0049] FIG. 11 is a clear score schematic according to the present invention and references, at 260 , an all scores cleared indication. At 262 , a further query is made if the protocol application is for tennis and, if yes, a succeeding series of indications are provided, at 264 , as to A/B score, game, set, error and match start particulars. At 266 , a clear game stat array command is given and, at 268 the protocol ends. If the query to 262 is no, a further query ( 270 ) requests if the application is for another type of game, e.g. racquetball, and then proceeds to repeat the protocol steps associated with that game and as previously described at 262 - 268 .
[0050] FIG. 12 is a further succeeding display mode schematic at 272 (see also again FIG. 2 ) and progresses to mode=display commend 274 and, subsequently, to game=declared query 276 . If no, game=1 set=1 indication is made at 278 and, if yes, query 280 posits whether button 3 (at 18 ) is depressed. If yes, select mode is referenced at 282 and, if no, query 284 asks as to whether button 1 is depressed. If yes, which=game indication is made at 286 and proceeds, if yes, to increasing a game or maximum game number at 288 . If the query to 286 is no, query 287 asks the set number being played (Which=set) and if yes, command 289 increments a set maximum whereas, and if no, protocol command advances to query 290 (also achieved by answering no to query 284 ) which posits whether button 2 is to be depressed. If yes, which=game query is referenced at 292 and, if yes, view=set indication is provided at 294 . If no to query 292 , which=set query is posited at 298 and, if yes, view=match indication is made at 296 and, if no, view=game indication at 300 .
[0051] Either of steps 296 and 300 , as well as a negative answer to query 290 , progress to a query at to pressing button 4 , at 302 . If yes, which=game query is made at 304 and, if yes again, which=set indication is made at 306 . If no to 304 , which=set query is posited at 308 and, if yes to that, which=match indication is made at 310 and, if no to 308 , which=game indication at 312 . If no to query 302 , further query 314 asks if button 5 is to be depressed. If yes, “to: time mode” indication is provided at 316 and, if no, view=game query is asked at 318 . If yes, “game# information” is provided at 320 . If no to 318 , view=set query is provided at 322 . Finally, a yes answer to query 322 progresses to a “set# info” indication at 324 or, if no to 322 , to a “match info” indication 326 , from any of 320 , 324 , or 326 commands, the display mode 272 repeats.
[0052] FIG. 13 is a final schematic illustration of the electronic scorekeeping device, at 328 , according to the present invention and which provides a selectable mode for different racquet sports including racquetball, badminton, and the like. In particular, mode=select indication is made at 330 and progresses to select command 332 . A further query, at 334 , asks whether type=declared and, if no, can reference type=tennis at 336 or, alternatively and if yes to 334 , query 338 asks if button 3 is to be pressed. If yes, the protocol proceeds to play mode 340 and, if no, query 342 asks (posits) if button 4 is to be pressed. If yes again, a type of game play selection is made and may include selected tennis ( 344 ), racquetball 346 or badminton 348 .
[0053] If yes to any of 344 , 346 , or 348 , a further selected one of “type=racquet” ( 350 ), “type=badmit” ( 352 ) or “type=tennis” ( 354 ) commands is given. If no to all, “type=tennis” ( 356 ) is selected as the default and proceeds to query 358 as to whether button 2 is to be pressed. If yes to that query, display 360 indicates a potential selection of a given level of game play, e.g., recreational, competition, tournament, etc., and, if no to 358 , further query 362 asks if button 5 is to be pressed. If yes to 362 , “time mode” indication is made at 364 and, if no, at 366 the protocol returns to display mode 328 .
[0054] The electronic scorekeeping device, according to any preferred variant, includes a power supply in the form of a watch battery and which is similar to that used with other conventional types of electronics, cameras, watches, etc. In a preferred application, the device 10 is universally applicable to all court-related sports and, potentially, other recreational sports. Additional features include built-in illumination, in the event of operating the watch in semi-darkness or other limited light conditions (see again lighted display face 12 and 32 in FIGS. 1 and 2 , respectively), a scratch-resistant display surface (e.g. sapphire crystal), audible signaling (e.g. a beep or chime sound to indicate match/set), as well as colorful designs and stylish arrangements to enhance the attractiveness of the device.
[0055] It is also envisioned that a single electronic wearable device can be programmed to operate according to all of the game play variants. Such a device can also be adapted to include other participant related games, beyond those described, and by which it is desirable to incorporate an electronic type device with processor capabilities for inputting scoring and other relevant parameters associated with game play (volleyball, handball, wallyball, etc.).
[0056] The previously described scoring protocol illustrations are relevant to the various embodiments of the present invention and which establish the manner in which the electronic device is manipulated according to a given game play variant. The protocol information is submitted as being exemplary only of one manner in which the electronic scorekeeping device is utilized and is not interpreted as limiting as to the manner in which the device may be configured or operated. It is also envisioned that the wearable scorekeeping device can be adapted to operate with other, non-racquet related sports including such as volleyball, or any other player/team participant sport related game or event.
[0057] Having described my invention, other and additional preferred embodiments will become apparent to those skilled in the art to which it pertains, and without deviating from the scope of the appended claims. | An electronic wearable scorekeeping device for use with a racquet/court-related sport. The device includes a body capable of being attached to a sport participant, such as by a wristband, strap or, suspending lanyard worn by the user. The body includes a display face and a maximum of five individually depressible buttons, these related to at least one of a selected game type, player score, play/display mode, advantage/UFE, and time mode. | 27,468 |
RIGHTS OF THE GOVERNMENT
The invention described herein may be manufactured, used and licensed by or for the United States Government for governmental purposes without the payment to me of any royalties thereon.
BACKGROUND OF THE INVENTION
The invention relates in general to the measurement of fluid pressure and, in particular, to a method and apparatus for converting an absolute fluid pressure to a differential fluid pressure.
In many fluidic circuits, it is necessary to convert the absolute pressure of a pressurized fluid to a differential pressure indicating the pressure of the pressurized fluid relative to a predetermined reference pressure. For example, in a pressure regulating circuit, a single pressure output signal from a rectifier may be used as a control signal to a differential circuit. If the desired reference pressure is available, the unknown pressure can be compared with the reference pressure in a differential amplifier.
However, in many applications, the desired reference signal is not available. In such a case, a passive circuit consisting of a parallel arrangement of an orifice and a capillary can be used to convert the unknown pressure into two flows which can be used as control pressure signals indicating the difference between the unknown pressure and a predetermined reference pressure. When the unknown pressure is correct, the flows are equal and no differential pressure occurs. When the pressure is low, more flow goes through the orifice giving rise to a differential signal in one direction. When the pressure is high, the flow is higher through the capillary giving rise to a differential signal in an opposite direction. Generally, pressure sensors for sensing an unknown fluid pressure inherently have a high input impedance. In this known arrangement, due to this high input impedance, the orifice will always contain a high content of linear or capillary features giving rise to a low sensitivity.
SUMMARY OF THE INVENTION
It is a primary object of the invention to provide a fluidic absolute-to-differential pressure converter which has a high sensitivity without requiring a reference pressure or a separate power supply.
It is another object of the invention to provide a method for converting a single fluid pressure to a differential fluid pressure which does not require a reference pressure source.
The method and apparatus according to the invention utilizes asymmetrical characteristics of laminar proportional amplifiers (LPA). By choosing an LPA designed in such a way as to have a severe mechanical offset, the differential pressure out at low pressures will favor one output over another. By then choosing a nozzle exit configuration and a control edge spacing which cause jet deflection to the opposite side when the gain of the LPA increases with supply pressure, then at high supply pressures, the jet will deflect and favor the other output. By adjusting the control resistance, the set point, i.e., zero differential between the two fluid outputs, can be controlled.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood, and further objects, features, and advantages thereof will become more apparent, from the following description of preferred embodiments, taken in conjunction with the accompanying drawings in which:
FIG. 1 is a plan view of a first embodiment of the invention;
FIG. 2 is a plan view of a second embodiment of the invention;
FIG. 3 is a plot of the LPA differential output signal versus the LPA input pressure signal;
FIG. 4 is a family of curves of LPA input versus output pressure signals for respective LPA control resistances; and
FIG. 5 is an electrical schematic diagram of a frequency control circuit which includes the absolute-to-differential pressure converter described herein.
DESCRIPTION OF PREFERRED EMBODIMENTS
The absolute-to-differential pressure converter 10 shown in FIG. 1 includes a supply input 12 which is disposed at one end of the converter 10 and is connected to receive a fluid whose absolute pressure is to be converted to a differential pressure indicating the pressure of the fluid relative to a desired reference pressure. Two fluid outlets 14, 16, separated by a splitter 18, are disposed at an opposite end of the converter 10. A supply nozzle 20 is connected in fluid communication with the supply input 12 to direct a fluid supply stream 22 from the supply input 12 into the converter 10 along a centerline 24 of the supply nozzle 22. The supply nozzle centerline 24 is offset in a lateral direction from the upstream end 26 of the splitter 18 by a distance 28 such that at least most of the supply stream 22 is directed by the supply nozzle 20 towards the output 14. For example, when the two outputs 14, 16 are disposed symmetrically on opposite sides of an axis 30 of the splitter, the splitter axis 30 can either be disposed in spaced parallel arrangement with the supply nozzle axis 24, as shown in FIG. 1, or can be disposed to intersect the supply nozzle axis 24 upstream of the splitter 18, as shown in FIG. 2, to achieve the desired lateral offset 28 of the supply nozzle centerline 24 at the splitter end 26.
Two control ports 32, 34 are connected to an available control fluid source through respective adjustable fluid resistors 36, 38, which may be either linear or nonlinear. For example, when the supply stream is formed of pressurized air, the ambient air surrounding the converter 10 can be used as the control fluid source for the control ports 32 and 34. When the fluid used to form the supply stream 22 is a liquid, the control fluid source for the control ports 32, 34 can be a low pressure return line of the fluid system.
The control ports 32 and 34 include respective control nozzles 40, 42, which are disposed on opposite sides of the supply stream 22 to establish fluid communication between the control ports 32, 34 and an interaction zone 44 which extends between the control nozzle 20 and the edges 46, 48 of two control nozzle vanes 50, 52, respectively. The two control nozzle vanes 50, 52 are disposed asymmetrically relative to the supply nozzle axis 24, wherein the vane edge 48 is disposed closer than the vane edge 46 to the axis 24. Since these vane edges 46, 48 determine not only the length but also the lateral extent of the interaction zone 44, this interaction zone 44 is also asymmetrically offset from the supply nozzle centerline 24.
The converter 10 also includes two sets of vents 54 and 56, 58 and 60, which are disposed on opposite sides of the supply stream path intermediate the interaction zone 44 and the outlets 14, 16, and which are open to ambient pressure to provide dumping points for fluid inside the converter 10.
Operation
When the fluid stream 22 is flowing through the converter 10, fluid from the available control fluid source will be drawn through two flow resistors 36, 38, through the two control ports 32, 34, and about the two control nozzle edges 46, 48, respectively, to become entrained with the supply stream 22. Assuming the two flow resistors 36, 38 are adjusted to the same value, more control fluid will be drawn into the supply stream 22 from the control port 34 than from the control port 32 because the control nozzle edge 48 associated with the control port 34 is disposed much closer to the edge of the supply stream 22 than is the control nozzle edge 46 associated with the control port 32. Consequently, the fluid pressure drop through the flow resistor 38 and the control port 34 will be greater than the pressure drop through the flow resistor 36 and the control port 32, and the pressure of the control fluid at the control nozzle 42 will be less than the pressure of the control fluid at the control nozzle 40. Because of this difference in the pressures exerted on opposite sides of the supply stream 22 in the interaction zone 44, the supply stream 22 will be diverted in the direction of the output 16. Thus, the mechanical offset of the control nozzle vanes 50, 52 in one lateral direction from the supply nozzle axis 24 produces an opposite effect on the differential pressure output signal between the two outputs 14, 16 from that of the mechanical offset of the splitter 18 in an opposite lateral direction from the supply nozzle axis 24.
FIGS. 3 and 4 show various curves of the supply pressure P s at the converter supply input 12 versus the differential pressure ΔP produced between the two converter outputs 14 and 16. In order to indicate whether the pressure at one output 14 is greater or less than the pressure at the other output 16, the differential pressure ΔP has arbitrarily been designated as a positive value when the pressure at the output 14 is greater than the pressure at the output 16, and as a negative value whenever the pressure at the output 14 is less than the pressure at the output 16.
Curve 62, shown as a dashed line in FIG. 3, is a plot of the supply pressure P s versus the differential pressure ΔP which would be produced between the two outputs 14, 16 of the converter 10 solely as a result of the mechanical offset of the splitter 18 described above. Curve 62 shows that this mechanical offset of the splitter causes the output differential pressure ΔP to monotonically increase in the positive direction with an increase in the supply pressure P s . The rate of change of the output differential pressure ΔP increases due to a reduction of viscous losses as the supply pressure P s increases.
Curve 64, shown as a dotted line in FIG. 3, is a plot of the supply pressure P s versus the output differential pressure ΔP which would be produced solely as a result of the mechanical offset of the control nozzle vanes 50, 52, described above. As shown by curve 64, the mechanical offset of the control nozzle vanes 50, 52 results in a nonlinear change in the output differential pressure ΔP as a function of increasing supply pressure P s . Essentially no change in the output differential pressure ΔP is produced at low supply pressures since there is no LPA gain. Thereafter, when the gain becomes appreciable, the output differential pressure ΔP rapidly increases in the negative direction.
Curve 66, shown as a solid line in FIG. 3, shows a plot of the supply pressure P s versus the output differential pressure ΔP produced as a result of the control nozzle vanes 50, 52 and the flow splitter 18 being oppositely offset from the supply nozzle centerline 24. Curve 66 clearly shows that these two mechanical offsets produce opposite effects on the output differential pressure ΔP. At low supply pressures P s , the effect of the mechanical offset of the flow splitter 18 predominates, and the output differential pressure ΔP increases the positive direction with increasing supply of pressure P s . Thereafter, as the supply P s continues to increase, the effect of the mechanical offset of the control nozzle vanes 50, 52 predominate, and the output differential pressure ΔP increases in the opposite negative direction. The geometry of the converter 10 can be set so that the output differential pressure ΔP is zero at the desired reference pressure P r . The slope of the curve 66 corresponds to the converter sensitivity. Typically, the value of (ΔP)/ΔP s is in the range of about 0.1 to 2.0 at the reference pressure P r .
The supply pressure P s at which the output differential pressure ΔP crosses zero, corresponding to the desired referenced pressure, can be varied by varying the resistance value of either flow resistor 36 or 38. If the resistance of the flow resistor 38 is increased, the jet edge pressure adjacent to vane edge 48 will be reduced by restriction of the entrained flow of control fluid, and the jet deflection will be augmented. Similarly, an increase in the resistance value of the flow resistor 36 will cause less jet deflection. By varying the ratio of the two flow resistors 36 and 38, the zero crossing or set point P r of the output differential pressure can be adjusted, as seen in FIG. 4.
The curve shown by a solid line in FIG. 4 is a plot of the supply pressure P s versus the differential pressure ΔP where the resistance R 38 of the flow resistor 38 is equal to the resistance R 36 of the flow resistor 36. This curve can be changed to that shown by a dashed line in FIG. 4 to thus raise the set point P r to P r ' by either increasing the resistance R 36 of the flow resistor 36 or decreasing the resistance R 36 of the flow resistor 38 so that R 38 <R 36 . Similarly, the curve can be changed to that shown by a dotted line in FIG. 4 to lower the set point P r to P r " by either increasing the resistance R 38 of the flow resistor 38 or decreasing the resistance R 36 of the flow resistor 36 so that R 38 >R 36 .
An example of a fluidic absolute-to-differential pressure converter 10, such as shown in FIG. 1, is seen below. In this example, the pressurized fluid is pressurized air and the control fluid is air at atmospheric pressure. The converter 10 has a supply flow rate of 0.3 liters per minute through the converter at 4 mm of Hg supply pressure through a supply nozzle 20 with a cross-section of 0.02×0.02 inches. The fluid outputs 14 and 16 are 0.027 inches wide by 0.020 inches deep. The flow splitter 18 has a rounded upstream end 26 of approximately 0.005 inch radius which is spaced from the supply nozzle 20 by a distance of approximately 0.180 inch. The flow centerline 30 of the splitter 18 is offset 0.005 inch from the supply nozzle centerline 24 in one lateral direction, and the centerline of the control nozzle vanes 50, 52 are offset 0.001 inch from the supply nozzle centerline 24 in an opposite lateral direction, as shown in FIG. 1. The edge 46 of the control nozzle vane 50 is spaced approximately 0.0135 inch from the centerline 24, and the control nozzle vane 52 is spaced approximately 0.0115 inch from the centerline 24. The two control nozzle vanes 50, 52 are disposed downstream from the supply nozzle 20 by a distance of approximately 0.02 inch along the centerline 24. When the atmospheric vents or flow resistors 36, 38 have equal flow resistances, an absolute-to-differential pressure converter of this design produces a differential pressure between the two outputs 14, 16 of the value of zero at the stated supply pressure of 4 mm of Hg.
A typical application of the invention described herein can be seen in FIG. 5. FIG. 5 discloses a fluidic automatic frequency control circuit 70 where the frequency impulses from a fluid oscillator frequency generator 72 are converted to the output pressure of the fluid frequency-to-analog convertor 74. The output pressure of the f/A converter 74 is converted to a differential pressure in the fluid outputs of an absolute-to-differential pressure converter 10, as described above. This differential signal is then fed to a high gain amplifier controller 76, which utilizes this signal to provide a feedback signal 78 in the form of an adjusted supply pressure to the frequency generator 72. The differential signals from the fluid absolute-to-differential converter 10 can also be used as control inputs in an array of fluid amplifiers downstream from the absolute-to-differential converter to form a pressure regulator with no moving parts.
One advantage of the absolute-to-differential pressure converter described herein is that it has the low output impedance of an LPA and readily matches into other LPA circuitry. Also, a high input impedance is possible by the choice of a supply nozzle size that does not affect sensitivity. Further, this converter requires neither a separate power supply nor a pressure reference. It has the advantage over mechanical devices such as pressure regulators in that it includes no moving parts, and is thus highly reliable, and there is no mechanical friction forces to overcome, thus giving response to any pressure changes.
Since many modifications, variations, and additions to the invention are possible within the spirit of the invention in addition to the specific embodiments described herein, it is intended that the scope of the invention be limited only by the appended claims. | A method and apparatus for converting the absolute pressure of a pressuri fluid to a differential pressure indicating the fluid pressure relative to a reference pressure. The pressurized fluid is directed asymmetrically into a laminar proportional amplifier (LPA) along a centerline toward a first of two outlets at a velocity determined by the fluid pressure. The LPA includes first and second control inlets disposed on opposite sides of the directed fluid jet and connected to a common source of control fluid, the first control inlet being disposed on the same side as the first outlet, and the second control inlet being disposed on the same side as the second outlet. The first and second control inlets include respective first and second downstream control edges which are asymmetrically disposed on opposite sides of the jet, with the second control edge being disposed closer than the first control edge to the centerline; consequently, the jet is deflected towards the second outlet in accordance with the jet velocity such that the differential pressure generated by the jet between the first and second outlets is zero when the fluid pressure is equal to the reference pressure. | 16,392 |
RELATED PATENTS
This application is a divisional of U.S. patent application Ser. No. 07/952,071 filed on Sep. 25, 1992.
FIELD OF THE INVENTION
The invention relates to mail processing and delivery systems and more particularly to cancelling apparatus which is adapted to mark or "cancel" the postage affixed to or printed on a mailpiece to prevent its reuse.
BACKGROUND OF THE INVENTION
In typical mail distribution operations at the various post offices worldwide, the metered and stamped mail is received in enormous volumes. In large mail distribution centers, if the mailpieces carry an imprinted indicia, the mailpieces are processed by sorters to sort the mail to its destination or in the event that the mailpiece has an affixed stamp, it is processed by the so-called facer-canceller which can orient the mailpiece cancel the stamp prior to the sorting of these mailpieces. In either case the actual weight of the mailpiece is normally never checked during the course of these operations.
As is well known in the United States and in many other countries, the postage amount required for delivery increases with the weight and size of the mailpiece. Accordingly, the Post Office will lose revenue on its delivery if in fact the postal rate (according to the postal Weight-Rate Tables) corresponding to the weight and/or size of the mailpiece exceeds the postage paid. In fact, one of the major factors contributing to loss of revenue is perceived to be the underpayment for individual mailpieces, and particularly those individual mailpieces being sent in batch mailings. In the conventional postal delivery systems, however, the costs associated with verifying the correct postage on an individual mailpiece may be prohibitive in terms of employee time since each piece to be verified must be manually extracted and individually weighed and rated either at entry into the mailstream or at some time during subsequent mail processing and delivery.
For batch mailings, there is normally a manual sampling and rating of mailpieces prior to merging them into the mailstream at the facility, but it will be appreciated that this sampling is at best inefficient because of possible human errors and the small sample size of such manual checking.
U.S. Pat. No. 5,072,400 to Mandulay discloses a system for monitoring the integrity of mail pieces passing through the delivery system for tracking and prevention of theft. In this system a data base is updated to include the initial weight and destination address of a mailpiece. As the mailpiece moves through the system the weight and the destination data are compared at the various stages to determine any discrepancies.
U.S. Pat. No. 5,019,991 to Sansone et.al., entitled CERTIFIED WEIGHER-SHORT PAID MAIL describes a system for assuring the post office that the weight of a mailpiece which would ordinarily require more postage was correctly accounted with consideration to other postage discounts, for 25 example, number of mailpieces being sent to a particular ZIP-code. U.S. Pat. No. 5,008,827 to Sansone, et.al., entitled CENTRAL POSTAGE DATA COMMUNICATION NETWORK describes a user system for certifying by marking a pre-posted mailpiece that any required additional postage due on the mailpiece has been accounted for to the post office.
While each of these work well for the intended purposes, they do not address the problem of routinely assuring that mailpieces which may enter the mailstream at the post offices from the counter, letter boxes or in batch mailings carry sufficient postage. The teaching of the '400 patent also requires the use of extensive computer facilities for maintaining the database and for certifying and protecting the accounting for postage.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide a novel method and apparatus for verifying that the required postage amount is affixed to a mailpiece.
It is a further object to provide a method and apparatus for automatic verification of batches of mailpieces.
These and other objects of the invention are realized in an apparatus for verifying postage paid comprising a facet means operative for orienting and presenting mailpieces for cancelling of postage affixed thereto; a weighing module for receiving a mailpiece having postage affixed thereon from the facet means and weighing said mailpiece; printing means; a transport means for transporting the mailpiece from the weighing module to the printing means; said printing means being operative for marking on said mailpiece a cancelling marking corresponding to correct postage for the mailpiece in correspondence with a determined rating and a weight as determined by the weighing means, whereby the marking enables comparison between postage affixed to the mailpiece and the actual value of required postage for delivery of the mailpiece.
In a second embodiment the apparatus comprises a data entry means and a display for input and output of data relating to a batch of mail; a weighing module for weighing a mailpiece having postage affixed thereon; scanning means for reading character information from the mailpiece; printing means; a transport means for transporting the mailpiece for scanning thereof from the weighing module to the printing means; said printing means being selectably operable for marking on said mailpiece a marking corresponding to correct postage for the mailpiece in correspondence with a weight as determined by the weighing means and rating information determinable from scanning of said mailpiece, whereby the marking enables comparison between postage affixed to the mailpiece and the actual value of required postage for delivery of the mailpiece.
In another aspect there is provided a method for verifying the postage on a mailpiece having postage affixed thereto comprising the steps of weighing a mailpiece having postage previously affixed thereto, setting a printing mechanism adapted for printing postal value to a value corresponding to a weight obtained from the weighing of said mailpiece, and cancelling the previously affixed postage using said printing mechanism to provide a cancellation mark that includes a value of postage calculated from rating information and the weight obtained from the weighing step.
In any of the foregoing aspects of the invention, the printing means may further comprise means operative for printing the date of cancellation.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a block diagram of a cancelling apparatus in accordance with the invention.
FIG. 2 is a flow chart of the basic operation of the cancelling process in accordance with the invention.
FIG. 3 is a block diagram of another embodiment of an apparatus particularly adapted for verifying larger batches of mail.
FIG. 4 is a flow chart of the method for verifying postage in accordance with the invention in respect of the apparatus of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1, there is shown generally at 10 a block diagram of a postage verifying system in accordance with the invention. The apparatus comprises a racer 12 which may be a conventional racer portion of a conventional facer-canceller, such as those typically used in the present mail-distribution facilities of the Post Office.
The facer 12 receives a mailpiece indicated at 14 from the input hopper 16 which holds the mailpieces to be verified and orients the mailpiece in conventional manner to position the mailpiece in the proper position for cancelling of the postage stamp (or meter impression). The term postage affixed to a mailpiece as used herein shall refer to both stamps and meter impressions signifying that value has been paid for the sending of the mailpiece. In accordance with the invention, instead of being transported as previously known to the conventional canceller section of the facer-canceller, the oriented mailpiece 14 is delivered by a mailpiece transport such as the continuous belt indicated at 18 to the input hopper 20 of a mailing machine comprising feeder section 22 which includes a transport 24 and an electronic postage meter section at 26. Mailpieces such as the mailpiece 14 placed on the hopper 20 are serially fed to the meter section 26 for overprinting of a cancelling indicia by a printing mechanism shown in block 28. The cancelling indicia printed by printing mechanism 28 includes postage value and, if desired or required by Post Office regulations for example, the current date. The mailing machine feeder section 22 includes scale 30 for weighing the mailpiece and communicating its weight to a microprocessor control apparatus 32 so that the appropriate postage value may be imprinted on the mailpiece as communicated either directly to the meter or by way of the microprocessor control apparatus 32. In the preferred embodiment illustrated here, the meter section 26 comprises a detachable meter which may be easily removed and replaced by similar types of meter apparatus having other features as described below.
If desired, a suitable keyboard 34 and display 36 communicate with the microprocessor control apparatus 32 for input and output of information in relation to scale 30, meter section 26, and transport 24.
A more detailed description of a suitable mailing machine is described in U.S. Pat. No. 4,935,078 entitled High Throughput Mailing Machine Timing, assigned to the assignee of the instant application and specifically incorporated by reference herein.
It will be appreciated by those skilled in the art that in order to provide the cancelling function in accordance with the invention, the inking of the indicia normally associated with postage metering function must be changed to be indelible ink, for example the conventional ink used by a Postal Authority, in order to prevent the washing of stamps for reuse. Other colors may also be used, if desired for instance, to distinguish the mailpieces that have been cancelled by the apparatus in accordance with the invention from the conventional cancellations of the Postal Authority.
It will also be understood that the printer which in a preferred embodiment is a postage meter printer, is not required in the instant situation to account for funds expended and therefore the accounting routines and security measures normally associated with the known meters may be simplified. While it is not believed necessary to change the format of the indicia typically used for imprinted postage meter indicias, except as necessary to distinguish it from valid postage meter impressions, it will also be appreciated that other markings are also contemplated in the event that a particular figure is required to allow the underlying value on the previously affixed postage to be readable.
In operation of the apparatus of FIG. 1 as seen in conjunction with the flowchart as illustrated in FIG. 2, the mailpieces having previously affixed postage are placed in the hopper 16 of the facet portion where the individual mailpieces are oriented and fed to hopper 20 of the mailing machine feeder section 22. The mailpiece is weighed, block 60 of FIG. 2, and the printer is set for the current date and appropriate postage, block 70, in accordance with the weight of the mailpiece and pertinent rating information as stored in the microprocessor control 32 or input through keyboard 34 or other input means. As the mailpiece is transported through the meter portion, an indicia including the date and valid postage amount for the particular mailpiece is printed over the previously affixed postage amount, block 80, thereby allowing easy comparison by a postal route carrier or other Post Office official to determine whether additional postage is due while at the same time cancelling the previously affixed postage. It will be appreciated that the mark showing the amount of postage required may be placed anywhere on the mailpiece so long as the cancelling of the previously affixed postage is also accomplished.
FIG. 3 shows another embodiment of the invention 5 particularly adapted for verification of larger batches of mail wherein the electronic meter section shown at 26' further comprises a scanner 38, such as, for example, one of the well known OCR readers and/or postal bar code readers, which is operative to read address as well as other determined information and the value of the postage affixed to the mailpiece as well as any presort and barcode information if desired, in order to capture additional information such as the address and the affixed postal amount. It will be understood that the scanner can be placed at other positions along the path of the mailpiece, however when located in the meter section in cooperation with the printer, the replacement of the meter unit with the scanner printer is enabled in a particularly convenient manner.
In a preferred embodiment, the printing mechanism may be made to operate selectably where it is desired to simply store the information in relation to the scanned mailpieces and compare the actual total postage due with the amount submitted by the sender, for example, on a manifest. This result may then be printed at the end of the run either by the printing mechanism 28 or by a separate printer (not shown) for comparison to a manifest or other documentation.
It should be noted that in FIG. 3 those modules which are unchanged from FIG. 1 retain the same numbers. Additional mailpiece measurement apparatus indicated at block 40 may also be included to determine the sizes of the pieces in order to further determine if a particular rating should be applied. This may be a separate module, but it could also be conventional photodiode detectors, arranged as required in the transport path at a convenient point, which are blocked and unblocked by various sized mailpieces
If required, additional memories shown at 42 for storage of information and look-up tables may be added in known manner to communicate with the microprocessor control 32. Similarly, the required input data and output data from the mailing machine control 32 may be obtained from and/or fed to additional computers or data storage devices not shown. The mailpieces may be sent to an optional sorter 44 for further processing if desired.
FIG. 4 illustrates the method for verification using the apparatus of FIG. 3. The first step indicated at 100 is sampling of the batch of mail submitted for verification. It will be understood that the sample may include the entire batch of mailpieces in a particular mailing, but this is believed to be inefficient and not necessarily required for adequate verification of a batch of mail.
Two attributes of the sampling have been found to be important. The first is to assure that the sample is random, in other words, that the selected pieces are not biased in terms of belonging to a group not with a specific property not present in other members of the batch. It will be understood that randomness can never be guaranteed; however, it is believed that standard measures such as selecting mailpieces from different sources and places, having different size, weight and make-up can establish reasonable randomness of the sample.
The second important attribute is the size of the sample taken. The size of the sample in a sense guarantees representativeness of the sample. It will be appreciated that the size of the sample can be determined using well-known statistical procedures. See, for example, Snedecor and Cochran, Statistical Methods, The Iowa State University Press, 1979. The size of the sample is a function of the allowable error, the desired confidence level and the estimated size of the batch.
It has been found, by way of example only and not as a limitation, that even for a very large mailing, a 1% error having a 95% confidence level defines the size of sample as 1,475 mailpieces assuming a binomial distribution for correct/incorrect postage and probability of success (correct postage) at 96% and probability of incorrect postage 4%. With a mailing machine capability of processing, for example, only 3000 pieces per hour, a sample of this size may be processed in about 30 minutes.
For best results, the determination can be carried out under control of the microprocessor control 32 and the sample size displayed as a result of operator input as to size of the batch, allowed error and confidence level. After entry of the data by the operator the required sample size is displayed.
Once the sample size is determined the mailpieces are selected and processed. As the individual mailpieces are fed through the mailing machine, the geometrical dimensions are obtained, block 110; the weight is obtained, block 120; the level of standardization, that is, the depth and format of the postal code present on the mailpiece is determined, block 130; the level of service, for example, desired delivery time is obtained, block 140; the group property or presort level is obtained, block 150; the declared or printed postage value is read, block 160; and the class and other special services are obtained, block 170.
The proper postage rate for a given mailpiece is then computed using the data elements thus obtained, block 180. It will be appreciated that this computation can either be by way of algorithm or simply by using a look-up table which has multiple discrete entries for size, weight, level of service, etc.
It will be understood that where the postage rate is also determined by the level of presort, this group property is not determinable from a single mailpiece. In this case it will be appreciated that the entire group of mailpieces which belong to the same sorting entity must be included in the sample and in this case the assurance of sample randomness is more difficult.
If the individual mailpieces are collected from street boxes, for example, at the YES branch of decision block 190, the sorter 44 may be set to outsort or otherwise flag mailpieces for which the determined postage rating value fails to match the amount affixed to the mailpiece, block 200. The incorrectly postaged mailpieces can be returned to sender for insufficient postage.
In the alternative, particularly where the mailpieces have no printed evidence of postage to compare, at the NO branch of block 190, the postage due for the mailpiece is added to a running total, block 210, and the routine loops back to repeat the checking of the next mailpiece. When the last mailpiece is checked, decision block 220, the postage due for the entire mailing is computed based on the verified sample and printed out along with the allowed margin for error, block 230. This total can be compared with the manifested value of the mailing and additional postage can be levied in the event the discrepancy exceeds some specified value. It will be appreciated that if desired the value determined for each mailpiece could be printed on the mailpiece to provide proof of checking in this situation as well.
It will be understood that the embodiment illustrated in FIG. 3 can also be simplified to operate in a semiautomatic mode. Such a system may, for example, require manual input of the information obtained as a result of the scanning and recognition process. In a simple implementation, the postage amount and postal code are displayed to the operator who enters these via the keyboard 34. The postal rate is computed and printed over the previously affixed postage and the incorrectly postaged mailpieces are outsorted as previously described.
It will be further appreciated that a particularly efficient operation is obtained in the apparatus in accordance with the invention for those batches of mailpieces in which each mailpiece is anticipated to require the same amount of postage (shown at 230). For instance, in the U.S. the apparatus might be set to 29 cents for mailpieces weighing an oz. or less. In such case the mailpieces could be efficiently scanned to outsort those mailpieces carrying insufficient affixed postage with no further operator input required beyond the initial setup for the anticipated rate.
In another mode of operation (shown at 240) information may be provided to the apparatus from an external source (such as a floppy disk), describing the amount of postage required by each mailpiece in a group to be processed. | The method and apparatus for verifying that the correct postage has been paid includes a mail processing machine which is adapted to receive properly oriented mail via a transport from a racer apparatus. The mail processing machine includes a scale for weighing a mailpiece having postage affixed thereto for the purpose of cancelling it with a mark which includes the actual postage which should be affixed. In a further embodiment other information necessary to calculate the necessary postage is obtained by reading the information from the mailpiece. Any discrepancies between the postage affixed and the amount of postage which should actually be paid may be noted at acceptance or seen by the carrier as the mail is delivered. A batch of mail may be sampled to select representative mailpieces in a random manner and verified to compare the calculated total of postage required based on the sample to the postal amount paid for the batch by the sender. | 20,612 |
TECHNICAL FIELD
An embodiment of the disclosure relates to techniques for generating a controlled voltage and more particularly to the methods for controlling a switching regulator.
BACKGROUND
A block diagram of a voltage regulator that supplies a load L through a cable C is depicted in FIG. 1 . A control system keeps the voltage generated by the converter at a constant value when changes of the input voltage Vin and/or the load L occur.
Optionally, a second control system may be present to regulate the current delivered by the converter.
The two control systems are mutually exclusive: if the current demanded by the load is lower than the current regulation setpoint, the voltage control system will regulate the output voltage and the current control system will be inoperative; contrarily, the current control system will take over and the voltage loop will be inoperative. Voltage control and, when present, current control use a closed-loop negative feedback: the voltage generated by the converter and current through the load, respectively V OUT and I OUT , are fed back to the error amplifiers EAV and EAC and they are compared with their references V REF and I REF , respectively.
The input signals V CV , V CC to the controller come from the error amplifiers that sense the difference between reference values (V REF and I REF ) and the feedback signals (V OUT and I OUT ). Depending on the input signals, the controller generates a PWM signal that drives power switches. Through a transformer, an output rectifier and a filter, energy is transferred from the supply voltage source V IN to the load L. The diagram shown in FIG. 1 is quite general and may have several possible alternative embodiments.
Typically, energy is transferred to the load through a cable C. The voltage control loop keeps the voltage Vout regulated but, depending on the output current, the voltage on the load, V LOAD , will be affected by a voltage drop along the cable, out of the control loop. Thus if a zero load regulation is to be achieved, it may be necessary to compensate the drop along the cable in some way.
A simple known way of meeting this potential need is illustrated in FIG. 2 and consists in using an additional sensing wire to sense the voltage V LOAD . In this way a zero load regulation may be achieved, but an additional wire is needed. A three-wire cable is not as common as a two-wire one and may be more expensive.
Another solution, that avoids the need of additional wires, is to adjust the voltage loop reference (V REF ) by an amount proportional to the average output current, the value of which can be sensed directly even with a remote load. Cable drop compensation (briefly CDC) can be performed if the value of the cable resistance R cable is known. This solution is depicted in FIG. 3 .
The transfer function of the CDC block is:
V′ REF =V REF +k CDC ·I OUT ,
where k CDC is the cable drop compensation gain and V′ REF is the adjusted reference.
In the circuit of FIG. 1 , during voltage regulation, it is:
V OUT =k CV ·V REF and V LOAD =V OUT −R cable ·I OUT ,
where k CV is the voltage loop gain, V OUT is the regulated voltage and V LOAD is the real voltage on the load.
With reference to the diagram of the FIG. 3 the output voltage is:
V′ OUT =k CV ·V′ REF =k CV ·( V REF +k CDC ·I OUT )= V OUT +k CV ·k CDC ·I OUT .
As the resistance R cable is known by the application, the k CDC value is chosen in order to satisfy the condition V LOAD =V OUT , hence:
k
CV
·
k
CDC
=
R
cable
⇒
k
CDC
=
R
cable
k
CV
.
Typically, the output current is sensed directly.
A common way of sensing the output current and adjusting the voltage reference proportionally in a non-isolated step-down switching converter is illustrated in FIG. 4 (from the STMicroelectronics AN1061 applications note, all versions of which are incorporated by reference). In particular, by connecting the resistor R K as shown in FIG. 4 , it is possible to adjust the voltage reference value by shifting the ground voltage of the IC by an amount proportional to the current I LOAD .
A similar technique applied to an isolated flyback switching converter is shown in FIG. 5 (from the STMicroelectronics TSM1052 datasheet, all versions of which are incorporated by reference). Only the secondary side is shown; V OUT and I OUT are sensed and compared against their respective references; the error signal (of the loop in control) is transferred to the primary side via an optocoupler, where it is properly handled.
A typical isolated flyback configuration using the optocoupler to transfer the output information from secondary side to the primary one is shown in FIG. 6 (from the STMicroelectronics Viper53 datasheet, all versions of which are incorporated by reference).
There is a special class of low-cost isolated converters, in which output voltage regulation is quite loosely specified and use a simpler approach, according to which there is no sensing element or any reference on the secondary side and, therefore, no specific means for crossing the isolation barrier to transfer the error signal to the primary side, as depicted in FIG. 7 (from the STMicroelectronics Viper53 datasheet, all versions of which are incorporated by reference). In these systems, the voltage drop along the output cable adds to their inherently poor load regulation and can make unacceptable the use of such low-cost systems. In this case, a cable drop compensation circuit would make the difference. However, there is no known technique to compensate the cable resistance for this type of switching converter.
SUMMARY
It has been found that it is possible to use the technique of adjusting the voltage reference even in flyback switching converters that do not have any voltage or current sensing means on the secondary side, and also do not have means for transferring an error signal from the secondary side to the primary side of the converter.
It has been demonstrated that the average output current delivered by the converter may be accurately estimated using signals available on the primary side, by providing a dedicated circuit block for estimating such a value.
More precisely, the average output current I OUT is proportional to the product of Is and the ratio T ONSEC /T wherein I S is the secondary peak current, T ONSEC is the time during which the secondary current is flowing and T is the switching cycle.
It has been found that signals accurately proportional to the ratio T ONSEC /T and to I S can be extracted from the primary side in any switching converter with primary feedback, thus it is not necessary to use dedicated sensors nor means for crossing the isolation barrier from the secondary side to the primary side.
For example, a signal accurately proportional to the ratio T ONSEC /T may be produced in different alternative ways:
measuring, with counters or with any other suitable digital means, the time interval T ONSEC in which the logic control signal that flags the beginning and the end of demagnetization phases is active and the duration T of the switching period; and calculating the ratio between the above times for producing a signal the level of which represents the ratio T ONSEC /T.
As an alternative, a signal proportional to the ratio T ONSEC /T may be produced by integrating over each switching period the logic control signal that flags the beginning and the end of demagnetization phases.
Another signal proportional to the ratio (T ONSEC /T) −1 may be obtained using the charge voltage of a filter capacitor on the primary side of the switching regulator that is discharged during each demagnetization phase by a resistor and is charged by a constant current in the remaining part of each switching period.
These signals representative of the current delivered to a load are used for estimating the voltage drop on the cable that connects the regulator to the load. Therefore, it is possible to control the effective voltage on the load instead of the voltage generated on the secondary side by the switching regulator.
Embodiments of the techniques herein described for estimating the output current of a flyback switching regulator without using sensing elements on the secondary side may be used also for other useful purposes.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a known architecture of a voltage regulator.
FIG. 2 depicts a known architecture of a voltage regulator using an additional sensing wire.
FIG. 3 depicts a known architecture of a voltage regulator with a compensation circuit for the voltage drop on the cable that connects the output of the regulator to a load.
FIG. 4 depicts a known architecture of a voltage regulator.
FIG. 5 depicts a known architecture of a voltage regulator.
FIG. 6 depicts a known architecture of a voltage regulator.
FIG. 7 depicts a known architecture of a voltage regulator.
FIG. 8 is a graph of typical current waveforms in the primary side and in the secondary side of a flyback switching regulator.
FIG. 9 reproduces a Zero Voltage Switching regulator disclosed in U.S. Pat. No. 6,590,789, which is incorporated by reference.
FIG. 10 depicts sample waveforms of the voltage across an auxiliary winding of the circuit of FIG. 9 for several values of the current absorbed by the load.
FIG. 11 reproduces a Zero Voltage Switching regulator disclosed in U.S. Pat. No. 5,729,443, which is incorporated by reference.
FIG. 12 is a graph of typical waveforms of the main signals of a Zero Voltage Switching regulator of FIG. 11 .
FIG. 13 depicts a first analog embodiment of a CDC circuit block for adjusting the reference voltage of a voltage error amplifier of a switching regulator.
FIG. 14 depicts a first embodiment of a switching regulator that includes a CDC block for adjusting the reference voltage.
FIG. 15 depicts an alternative embodiment of a switching regulator that includes a CDC block for adjusting the feedback voltage of the regulator.
FIG. 16 depicts another alternative embodiment of a switching regulator that includes a CDC block for adjusting the feedback voltage of the regulator.
FIG. 17 shows a first digital embodiment of a circuit for generating a signal proportional to the ratio T ONSEC /T.
FIG. 18 shows an alternative digital embodiment of a circuit for generating a signal proportional to the ratio T ONSEC /T.
FIG. 19 shows a first analog embodiment of a circuit for generating a signal proportional to the ratio T ONSEC /T.
FIG. 20 depicts an alternative analog embodiment of a circuit for generating a signal proportional to the ratio T ONSEC /T.
FIG. 21 depicts another embodiment of a switching regulator that includes the CDC block for adjusting the reference voltage and a circuit for generating a signal proportional to the ratio T ONSEC /T.
DETAILED DESCRIPTION
Primary and secondary sample current waveforms of a flyback switching converter working in discontinuous mode are depicted in FIG. 8 . It will be assumed that its PWM modulator uses a current mode control. The average output current I OUT is:
I OUT = I S 2 · T ONSEC T ,
where, I S is the secondary peak current, T ONSEC is the time during which the secondary current is flowing, and T is the switching-cycle period.
By adding a dedicated circuit, able to estimate the ratio T ONSEC /T, in the current mode IC controller, it is possible to calculate the I OUT , value by the above formula. This approach may be applied to any current-mode-controlled switching converter with primary feedback.
In order to better understand the gist of this technique, the functioning of an off-line all-primary-sensing switching regulator, disclosed in U.S. Pat. Nos. 5,729,443 and 6,590,789 (which are incorporated by reference) will be discussed.
An equivalent high-level circuit scheme of the switching regulator disclosed in U.S. Pat. No. 6,590,789 for regulating the output voltage is reproduced in FIG. 9 . An accurate image of the output voltage is obtained by sampling the voltage on the auxiliary winding immediately at the end of transformer's demagnetization phase, as illustrated in the graph of FIG. 10 . The switch Q 1 is turned on after the end of the demagnetization phase and then turned off by a comparator that monitors the source current of Q 1 using a sense resistor R S .
An equivalent high level circuit scheme of the switching regulator disclosed in U.S. Pat. No. 5,729,443 for regulating the output current is reproduced in FIG. 11 . The switch Q 1 is operated by the PWM signal, set by the end of the demagnetization phase of the transformer, and reset by a comparator that monitors the source current of Q 1 through the sense resistor R S .
The voltage of an auxiliary winding is used by a demagnetization block DEMAG through a protection resistor. The demagnetization block DEMAG generates a logic flag EOD that is high as long as the transformer delivers current to secondary side. Waveforms of the currents in the primary side and in the secondary side of the regulator, of the logic flag EOD , and of the current I C through the filter capacitor C during a switching period, are shown in FIG. 12 .
The logic flag EOD is used to turn on and off a MOSFET switch Q 2 for discharging/charging the filter capacitor C. A resistor R in series with it absorbs a current U C /R, where U C is the voltage across the capacitor C. This capacitor C filters the charge current I REF and the discharge current (I REF −U C /R) so that U C is practically a DC voltage, that is applied to an input of the current mode comparator.
At steady state, the average current I C is zero. If T ONSEC is the time during which the secondary current I S is flowing, it is:
I REF · ( T - T ONSEC ) + ( I REF - U C R ) · T ONSEC = 0 ,
which can be simplified in:
U
C
=
R
·
I
REF
·
T
T
ONSEC
(
1
)
The voltage U C is then used to set the peak primary current I p :
I P = U C R S ,
which defines the peak secondary current I S :
I
S
=
n
·
I
P
=
n
·
U
C
R
S
(
2
)
The average output current I OUT can be expressed as:
I
OUT
=
I
S
2
·
T
ONSEC
T
(
3
)
By combining the previous equations, we obtain:
I
OUT
=
n
2
·
R
·
I
REF
R
S
.
Thus it is possible to set the average output current of the switching regulator by fixing the reference current I REF and the resistances R and R S .
It has been found that a signal proportional to the output current can be generated by using signals already available in the primary side of the converter.
Indeed, combining equations (1) and (3), leads to the following expression:
U
C
=
R
·
I
REF
2
·
I
S
I
OUT
(
4
)
Hence the charge voltage of the filter capacitor contains information concerning the average output current, thus it can be used for compensating the voltage drop on the cable that connects a load to a flyback switching regulator.
Moreover, during the voltage regulation, the voltage control loop signal establishes the peak primary current I p :
I P = V CV R S ( 5 )
wherein V CV is the voltage generated by the error amplifier EAV (in the circuit of FIG. 1 ) proportional to the difference between the reference voltage V REF and the output voltage V OUT generated by the controller.
Therefore, by combining the equations (4) and (5) it results:
U
C
=
n
2
·
R
·
I
REF
R
S
·
V
CV
I
OUT
In the above formula all the signals are known except for the I OUT value.
In the IC controller is inserted a dedicated CDC block for performing the division between the signals V CV and U C in order to obtain a signal proportional to the output current:
V
CV
U
C
=
2
n
·
R
S
R
·
I
REF
·
I
OUT
(
6
)
In an embodiment, the CDC block is analog, as depicted in FIG. 13 , and comprises an analog divider the output of which is multiplied by a constant k, a filter and an analog subtractor of the output of the filter and the reference voltage V REF .
As an alternative, the CDC block could be digital, converting the signals V CV and U C in digital form, carrying out the division, subtracting the result from the voltage value V REF , and converting the result back into an analog signal.
The next step is to adjust the voltage reference V REF by an amount depending on the output current, as explained previously. In fact, the CDC block is designed to implement the following transfer function:
V
REF
′
=
V
REF
-
k
·
2
n
·
R
S
R
·
I
REF
·
I
OUT
.
The CDC block, during the output voltage regulation, introduces a positive feedback that may compromise the stability of the primary loop. For this reason a low-pass filter is preferably added, as shown in FIG. 13 .
Looking at FIG. 13 it is possible to notice the analog divider, the output signal of which is multiplied by a constant k, the filter and the analog subtractor.
FIG. 14 shows the architecture of an embodiment of a voltage mode converter, that includes a CDC block in the primary loop for adjusting the voltage reference value (V REF ) by an amount proportional to the output current. The new voltage loop reference is V REF ′. This allows to compensate the voltage drop along the output cable and, ideally, to achieve a zero load regulation.
This technique may be applied even by modifying the feedback voltage on the capacitor C* instead of directly acting on V REF . A sample embodiment of this type is shown in FIG. 15 , where the CDC block sinks a current proportional to the output current from the feedback resistor divider in order to modify the sampled value:
I
CDC
=
k
·
2
n
·
R
S
R
·
I
REF
·
I
OUT
.
Another way to modify the voltage feedback signal value is to generate a voltage proportional to the output current:
V CDC = V REF - k · 2 n · R S R · I REF · I OUT
and to connect a resistor R CDC as shown in the FIG. 16 . The resistor R CDC is an external component which gives the user the possibility to set the CDC gain depending on the application. Its value is calculated by the following equation:
R CDC = k · 2 n · N OUT N AUX · R 1 R cable · R S R · I REF ,
where, n is the ratio between primary and secondary windings, N OUT is the number of the windings on the secondary, N AUX is the number of the windings on the auxiliary, R cable is the cable resistance and R S is the sensing resistor connected to the power MOSFET source. The use of that resistor is a possible way to set the CDC gain depending on the application. In fact, applying the previous embodiments, without R CDC , the same objective can be reached by trimming the constant k value.
A signal proportional to the ratio T ONSEC /T may be generated by exploiting the logic control signal EOD that flags the beginning and the end of magnetization phases, for example using the embodiment of the circuit depicted in FIG. 17 . Two pulse counters COUNTER generate digital signals corresponding to the duration of the time intervals T ONSI and T−T ONSEC by counting clock pulses while the signal EOD and the inverted replica thereof are active, respectively, then a calculation block DIGITAL CALCULATOR generates a digital signal that represents the ratio T ONSEC /T, that is converted in a corresponding analog signal Vratio by a digital-to-analog converter DAC.
If the CDC block can be input with digital signals, then the converter DAC is not necessary.
According to an alternative embodiment, a signal proportional to the ratio T ONSEC /T may be generated by the circuit of FIG. 18 , that uses three monostable flip-flops for switching three capacitors C, C 1 and C 2 . In correspondence of the leading edge of the signal EOD , the charge voltage of the capacitor C is sampled and held on the capacitor C 1 , and the capacitor C is discharged (signal RESET). The capacitor C is charged again by the current generator IREF and its charge voltage is sampled and held on the capacitor C 2 when the signal EOD switches low (that is at the end of each demagnetization phase). Therefore, the charge voltages VC 1 and VC 2 of the capacitors C 1 and C 2 represent the duration of a period and of the magnetization phase, respectively:
V
C
1
=
I
REF
C
·
T
,
V
C
2
=
I
REF
C
·
T
ONSEC
A divider generates the signal Vratio as the ratio V C2 /V C1 .
The signal RESET used for discharging the capacitor C is substantially a delayed replica of the pulse T, such to zero the charge voltage of the capacitor C substantially immediately after it has been held on the capacitor C 1 .
According to an alternative embodiment, the voltage Vratio may be generated by integrating the signal EOD over a switching period T, as schematically depicted in FIG. 19 .
A CDC block suitable for using the voltage Vratio for adjusting the reference voltage VREF′ is depicted in FIG. 20 . This CDC block is similar to that depicted in FIG. 13 , but it has an input multiplier instead of an input divider.
An embodiment of a switching regulator that employs the CDC block of FIG. 20 and a circuit for generating a voltage Vratio proportional to the ratio T ONSEC /T, such as the circuits of FIGS. 17 to 19 , is shown in FIG. 21 . The functioning of this switching regulator is evident in view of the description made referring to FIGS. 14 to 16 . Furthermore, some to all of the components of the switching regulator of FIG. 21 may be disposed on an Integrated Circuit (IC) die, and the regulated output voltage V OUT may provide power to a circuit, such as a controller processor, that is disposed on the same die or on a different die.
Naturally, in order to satisfy local and specific requirements, a person skilled in the art may apply to the solution described above many modifications and alterations. Particularly, although the present subject matter has been described with a certain degree of particularity with reference to described embodiment(s) thereof, it should be understood that various omissions, substitutions and changes in the form and details as well as other embodiments are possible. Moreover, it is expressly intended that specific elements and/or method steps described in connection with any disclosed embodiment of the disclosure may be incorporated in any other embodiment as a general matter of design choice. | An embodiment of a power-supply controller comprises a switching-control circuit, an error amplifier, and a signal generator. The switching-control circuit is operable to control a switch coupled to a primary winding of a transformer, and the error amplifier has a first input node operable to receive a feedback signal, a second input node operable to receive a comparison signal, and an output node operable to provide a control signal to the switching-control circuit. The signal generator is operable to generate either the feedback signal or the comparison signal in response to a compensation signal that is isolated from a secondary winding of the transformer and that is proportional to a load current through a conductor disposed between the secondary winding and a load. | 32,933 |
This is a continuation of application Ser. No. 858,746 filed May 2, 1986, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a semiconductor module and, particularly, to a semiconductor module including switching devices as components of an inverter which is used in an uninterruptable constant-voltage constant-frequency (CVCF) power unit.
2. Description of the Prior Art
FIG. 1 is a block diagram showing the conventional semiconductor module and its associated switching control circuit taking charge of one phase of an inverter. In the figure, a PWM control circuit 1 has its output connected to a short-circuit prevention circuit 2, which provides outputs to drive circuits 3a and 3b. The drive circuits 3a and 3b supply their outputs to a semiconductor module 4 which incorporates two serial-connected self-turn-off switching devices, such as transistors and GTOs, Q1 and Q2.
FIG. 2 is a timing chart showing the input/output signals among the component blocks shown in FIG. 1. The chart includes the output signal S1 A of the PWM control circuit 1, the drive signal S1 B provided by the positive drive circuit 3a for the positive switching device Q1, the drive signal S1 C provided by the negative drive circuit 3b for the negative switching device Q2, and the output signal S1 D produced by the semiconductor module 4.
Next, the operation of the above-mentioned prior art system will be described. The PWM control circuit 1 determines the timing of activating or deactivating the switching devices Q1 and Q2 which constitute a phase arm of the inverter, and produces the output signal S1 A . A high output signal S1 A operates on the drive circuit 3a to produce the drive signal S1 B by which the positive switching device Q1 turns on, while the negative switching device Q2 does not receive its drive signal S1 C from the drive circuit 3b and stays in the off state. Conversely, a low output signal S1 A does not provide the drive signal S1 A for the positive switching device Q1, causing it to stay in the off state, while the negative switching device Q2 receives the drive signal S1 C from the drive circuit 3b and turns on.
In the transition of the output signal S1 A from high to low, or from low to high, namely when one switching device changes the state from on to off and another switching device from off to on, the main current in the turning-off switching device Q1 or Q2 goes off with a time lag of a carrier storage time plus a turn-off time with respect to the turn-off command by the drive signal S1 B or S1 C , resulting in an improper operating mode where both switching devices Q1 and Q2 are in the on state simultaneously (this state is termed here "vertical short-circuit").
In order to prevent the occurrence of vertical short-circuit, a short-circuit preventing circuit 2 is provided, and it causes the turning-on drive signal S1 B or S1 C to lag so that both switching devices Q1 and Q2 are given the off-command for a certain time length `t`. However, when the pulse width is narrow, as in the high-frequency PWM control, a time lag in the turn-on command causes the semiconductor module 4 to produce the output S1 D which is different in pulse width from the PWM control signal S1 A , and a theoretical output waveform which is free of specific harmonics cannot be accomplished.
SUMMARY OF THE INVENTION
A main object of the present invention is to provide a semiconductor module which effectively overcomes the foregoing prior art deficiency.
Another object of the invention is to provide a semiconductor module which minimizes the vertical short-circuit interrupting period for serial-connected switching devices and is capable of switching at a nearest timing to the PWM control signal.
Other objects and advantages of the present invention will become more apparent from the following description of the preferred embodiments taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing the conventional semiconductor module and its associated switching control circuit used for a phase arm of an inverter;
FIG. 2 is a timing chart showing the input/output signals among the component blocks shown in FIG. 1;
FIG. 3 is a block diagram showing an embodiment of the inventive semiconductor module and its associated switching control circuit used for a phase arm of an inverter;
FIG. 4 is a timing chart showing the input/output signals among the component blocks shown in FIG. 3; and
FIG. 5 is a block diagram showing another embodiment of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of the present invention will now be described with reference to FIG. 3, in which counterparts of FIG. 1 are referred to by the common symbols. Reference numbers 5a and 5b denote logical AND gates and reference number 6 denotes a semiconductor module. The semiconductor module 6 includes transistors Q3 and Q4 functioning as serial-connected switching devices and current sensors Q5 and Q6 for detecting the presence or absence of the emitter current of the transistors Q3 and Q4, with the outputs of the sensors Q5 and Q6 being connected to the inverting input of the AND gates 5a and 5b, respectively. A diode Q 9 is connected in parallel to the switching device Q 3 and current detector Q5 and a diode Q 10 is connected in parallel to the switching device Q 4 and current detector Q6 so as to bypass the switching devices and prevent reverse currents therethrough when the potential at the emitter side of the switching device becomes positive with respect to the potential at the collector side of the switching device.
The timing chart shown in FIG. 4 includes the output signal S2 A of the PWM control circuit 1, the base drive signal S2 B produced by the positive drive circuit 3a for controlling the operation of the positive switching device Q3, the base drive signal S2 C produced by the negative drive circuit 3b for controlling the operation of the negative switching device Q4, and the output signal S2 F of the semiconductor module 6. In FIG. 3, the current sensor Q5 detects the emitter current of the switching device Q3 and provides a logical output signal S2 D , while another current sensor Q6 detects the emitter current of the switching device Q4 and provides a logical output signal S2 E . The sensor output signals S2 D and S2 E have a variable transitional timing depending on the power-factor of the load circuit, and therefore are not shown in the timing chart of FIG. 4.
The operation of the foregoing circuit arrangement is as follows.
The PWM control circuit 1 determines the timing of switching for the switching transistors Q3 and Q4, by providing a high output S2 A to make a drive signal S2 B for turning on the transistor Q3 and providing a low output S2 A to make a drive signal S2 C for turning on the transistor Q4, as in the conventional system. The current sensors Q5 and Q6 detect the presence or absence of the emitter current of the transistors Q3 and Q4, and produce a high detection signal S2 D or S2 E or a low detection signal S2 D or S2 E in correspondence to the presence or absence of each emitter current.
When the output signal S2 A of the PWM control circuit 1 makes a transition from low to high in the presence of the emitter current of the transistor Q4, the detection signal S2 E goes high, causing the AND gate 5a to produce a low output signal S2 B , and the transistor Q3 is not turned on. At the subsequent moment when the emitter current of the transistor Q4 has gone off, the detection signal S2 E becomes low, causing the AND gate 5a to produce a high output signal, and the transistor Q3 is turned on by the drive signal from the drive circuit 3a.
Conversely, when the output signal S2 A of the PWM control circuit 1 makes a transition from high to low in the presence of the emitter current of the transistor Q3, the drive circuit 3b produces a low drive signal S2 C , retaining the transistor Q4 in the off state. The drive signal S2 C becomes high the moment Q3 emitter current has gone off, and the transistor Q4 is turned on. Accordingly, no time lag arises in the turn-on and turn-off operations of both switching devices in the moment of transition of one switching device from on to off and another switching device from off to on.
FIG. 5 shows another embodiment of this invention, in which the semiconductor module 6 is provided therein with base drive signal bypass circuits or transistors Q7 and Q8 which are controlled internally to become conductive so that the switching device Q3 or Q4 is forced to cut off, instead of using the external interlock circuit.
Although in the foregoing embodiments of FIGS. 3 and 5 the semiconductor module 6 is a transistor module, the switching devices may be other self-turn-off devices such as GTOs and MOSFETs to accomplish the same effect as described above.
The present invention is intended to prevent vertical short-circuitting of two switching devices in a semiconductor module by provision of current sensors which detect the presence or absence of the main current of the switching devices. The simple inventive circuit arrangement surely prevents the improper mode of operation in which two switching devices are in the on state simultaneously. In consequence, the switching devices produce the pulse width with much fidelity to the command waveform, whereby the inverter constituted by the semiconductor modules can have the enhanced performance. | A semiconductor module includes two switching devices operated by the PWM control signal, current detectors for detecting currents through the respective switching devices, and bypass units operated by the corresponding opposite current detector for shunting the control signal to the respective switching devices to prevent activation thereof when the corresponding opposite switching device is conductive. | 9,780 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a laser processing method and an apparatus of hole-boring, cutting or welding by irradiating objects (work pieces) with high power ultrashort pulse laser beams. Ultrashort pulse laser processing, which converges an ultrashort laser pulse by a lens and irradiates an object (a work piece) with the converged pulse, has an advantage of neither heating nor degenerating surrounding parts since heated regions are narrowly localized and ultrashort duration time gives no time of heat diffusion to the surrounding parts. The ultrashort pulse laser processing is a momentary, adiabatic processing. The ultrashort laser pulse processing is suitable for the processing of resins, glasses, quartz, sapphire, semiconductors, and so on.
This application claims the priority of Japanese Patent Application No. 2004-336944 filed on Nov. 22, 2004, which is incorporated herein by reference.
2. Description of Related Art
Japanese Patent Laying Open No. 2003-305585 “Laser processing and apparatus” pointed out a problem of the occurrence of color aberration caused by wavelength dispersion when an ultrashort pulse was converged by a refractive lens. Since the pulse width is very short, the wavelength does not take a constant value but fluctuates. Each lens material has an intrinsic refractive index dispersion (dn/dλ<0). The negative refractive index dispersion allocates shorter focal lengths to shorter wavelength rays and longer focal lengths to longer wavelength rays. Dispersion of the focal lengths degenerates convergence of the laser beam.
Japanese Patent Laying Open No. 2003-305585 proposed a hybrid lens having a refractive front surface and a diffractive rear surface as a lens of the ultrashort pulse laser processing. Diffractive lenses allocate longer focal lengths to shorter wavelength rays and shorter focal lengths to longer wavelength rays against refractive lenses. The function of a diffractive lens is contrary to the function of a refractive lens with regard to color aberration. Japanese Patent Laying Open No. 2003-305585 proposed a method of obtaining 0 color aberration by compensating the aberration induced by the refractive lens with the counter aberration caused by the diffraction lens. FIG. 1 shows a figure described in Japanese Patent Laying Open No. 2003-305585. The front surface ( 301 A) is a refractive plane and the rear surface ( 301 B) is a zigzag diffractive plane. The diffraction function cancels the color aberration caused by the refractive function in the optics in FIG. 1 .
SUMMARY OF THE INVENTION
Instantaneous processing requires laser beams to raise power density. Conventional laser beam processing makes use of a converging lens for concentrating beam power at a narrow region. However various kinds of aberration accompany refractive-type lenses. The aberration prevents the lenses from converging the laser beam to a desired narrow region. In the case of continual laser beam processing using a refractive-type lens, the aberration of refractive lenses is a problem. There are several kinds of aberration in refractive-type lenses. Pulse laser, in particular, ultrashort pulse laser processing causes new aberration owing to the narrowness of a pulse. This aberration originates not from lenses but from ultrashortness of a pulse. The new aberration is that the wavelength is no more a single one and has a definite range. An ultrashort pulse laser beam loses monochromacity. The pulse laser beam including a definite continual range of wavelengths may be called a “multiwavelength” beam. Color aberration is caused in an optical system of converging ultrashort laser pulses by a refractive type lens due to wavelength dispersion (dn/dΛ) of the lens material. Japanese Patent Laying Open No. 2003-305585 proposed an idea of cancelling the color aberration appearing in the pulse laser system using a refractive lens.
It is important to raise horizontal resolution in an xy-plane, which is orthogonal to the beam line (z-axis) in the laser processing which converges a laser beam at a narrow region. Sometimes laser beams are used for cutting, annealing or welding a part having a long depth (z-direction) of an object (a work piece). The depth (z-) direction processing requires a deep (long) focal depth. A shallow focal depth of a beam allows a small (z-direction) distance error to induce large dispersion of the beam power and invite shortage of power density at an object (a work piece) spot. A deep (long) local depth is important in the laser processing as well as a fine horizontal resolution. This invention aims to prolong the focal length.
Semiconductor industries have utilized photolithography. Photolithgraphy adopts size-reduction optical systems. Large aperture lenses are employed in photolithography. Resolution is given by k 1 λ/(NA), where k 1 is a constant determine by the lens shape, NA is a numerical aperture and λ is a wavelength of incident light. A focal depth is given by k 2 λ/(NA) 2 . Photolithgraphy, which relies upon an size-reduction optical system, employs a large aperture lens (a wide lens) having a large NA for raising resolution. A large NA shortens the focal depth k 2 λ/(NA) 2 . A shallow focal depth is undesirable, because light power does not penetrate into inner parts of a photoresist. Photolithography has tried to enlarge the focal depth for a large NA lens by enhancing k 2 . Resolution and focal depth contradict each other in photolithography.
Laser beam processing, which treats metals, ceramics or glasses with high power laser beams, requires not so high resolution as semiconductor photolithography. Laser beam processing requires a focal depth deeper than photolithography. A deep (long) focal depth is essential for laser beam processing to perforate holes piercing an object (a work piece) at a stroke.
Conventional laser processing apparatus does not employ a size-reducing optical system. A hole is bored on even a rigid object (a work piece), at length, by irradiating the object (a work piece) for enough time with a narrow continual laser beam. The focal depth has been insignificant for continual laser beam processings.
However, pulse laser processing, which bores a hole by a single pulse or a few pulses, requires a deep focal depth of lens-converged beams. In order to form a deep, constant-diameter hole with precision, the hole should be bored at a stroke by a single giant pulse. A deep focal depth is essential for the single pulse processing.
The refractive-type lenses employed in photolithography have the definite expression k 2 λ/(NA) 2 of the focal depth. On the contrary, no exact expression of the focal depth of the ultrashort pulse laser processing has been known. No attention has been paid to the study of the focal depth of the ultrashort pulse lasers.
The purpose of the present invention is to provide a method and an apparatus for prolonging the focal depth of the ultrashort pulse laser processing.
The present invention deepens the focal depth of the lens in the ultrashort pulse laser processing by converging pulse laser beams by a diffractive-type lens on a condition of keeping the Z-parameter Zp=2f 0 cΔt/Δi 2 less than 1 (Zp≦1). Here f 0 is a focal length of the diffraction-type lens, c is a light velocity in vacuum, Δt is a time pulse width FWHM (Full Width at Half Maximum), and Δi is an incident beam diameter FWHM.
An ordinary smoothly curved-surface lens relying upon refraction is called a refractive-type lens or a refractive lens in short for discerning other types of lenses. The refractive-type lens is an excellent lens having advantages of freedom from diffraction, little aberration, high efficiency of refraction and good convergence. However, the conventional refractive lens has a shallow focal thickness denoted by the equation k 2 λ/(NA) 2 . The poor foal depth is a problem of refractive lenses. A decrease of the numerical aperture NA will enlarge the focal depth. But the resolution will be degenerated by the decrement of NA. It is difficult to raise the shape factor k 2 by contriving the shape of a refractive lens. There is poor room for deepening the focal depth of refractive-type lenses at the cost of resolution.
The present invention employs a diffractive-type lens for accomplishing a deep focal depth instead of the conventional refractive-type lens. The diffractive lens has weak points in aberration, efficiency and cost. The Inventors have noticed that diffraction lens would have a probability of raising the focal depth performance. Properties of conventional refraction lenses are now briefly described for clarifying the properties of diffraction lenses. Functions of the refractive lenses are explained within the scope of thin lens approximation. The curvature radius of a thin lens is denoted by R. A thickness variation d(r) of a thin spherical lens is described in a second order function
d ( r )= d 0 −r 2 /2 R, (1)
where r is a radial coordinate measured from the center and d 0 is a thickness at the center of the lens. The thickness decreases as r increases. When the lens has both spherical surfaces, the curvature 1/R is allocated to both surfaces with 1/R 1 and 1/R 2 as 1/R=1/R 1 +1/R 2 . The focal length f is determined by f −1 =(n−1)(1/R 1 +1/R 2 ).
Here the lens is assumed to be a flat-convex lens for simplicity, since the purpose is to explain the function of a diffraction lens in contrast to a refraction lens. A flat-convex lens can easily be revised by replacing 1/R to 1/R 1 +1/R 2 for curvature radii of both surfaces.
The tangential slant of a lens part at radius r to the base plane is Y=r/R. The total bending angle of a beam in a prism has a top angle α is (n−1)α. When a ray goes into the lens at radius r, the ray bends by a total angle of (n−1)r/R. Parallel incidence rays are converged at a focus f. The bending angle (n−1)r/R should be equal to r/f. Namely r/f=(n−1)r/R. Under the assumption of the thin lens, the equality holds for all radius coordinates r. A unique value is determined for a focal length f. Thus the focal length f of a refractive type lens is given by
1/ f= ( n− 1)/ R. (2)
When the lens is a convex-convex lens, 1/R should be replaced by 1/R 1 +1/R 2 .
Eq. 2 teaches us that the focal length f of a refractive lens is determined by the curvature radius R and the refractive index n. A change of wavelengths λ has an influence upon the focal length f via the wavelength dispersion (dn/dλ). The wavelength dispersion (dn/dλ), which depends upon the lens materials, is very small. The change of the focal length induced by a change of wavelengths is very small in refractive lenses. Differentiation of Eq. (2) by λ yields
df/dλ=−f 2 ( dn/dλ )/ R. (3)
(dn/dλ) is a material dependent dispersion, which is very small for ordinary lens materials. Thus the focal length change is also small for refractive-type lenses.
The above gives an explanation of properties of refractive type lenses. The next object (a work piece) of consideration is Fresnel lenses. A Fresnel lens is composed of a set of many annular slants and annular precipices, which can be designed from a shape of a corresponding refractive type lens. When a ray passes a point of a thickness d(r) at a radius r, the optical path length in the lens is longer than that in vacuum by (n−1)d, which is a difference between a vacuum path length d and an in-lens path length nd.
φ( r )=−2π( n− 1) d ( r )/λ. (4)
Since (n−1)d induces retardation of phase, a minus sign appears in Eq. (4). Here d(r) is a thickness at a spot of a radius r of the lens. Eq. (4) is valid for general thicknesses d(r) including the case of Eq. (1).
FIG. 3 denotes schematic half sectional views of a refractive lens (a), a Fresnel lens (b) and a binary lens (c) as functions of a radius coordinate r. The bottom figure is a half section of the refractive type lens (a), which has a smooth surface having a thickness distribution expressed by Eq. (1). The Fresnel lens (b) is made from the refractive lens by circularly dividing the smooth spherical surface (a) at every decrease of a unit height λ/(n−1), lifting annular partial slants up to the top level and making a set of discontinual annular slants and annular precipices. The Fresnel lens (b) of FIG. 3 has many steps (precipices) of the height of λ/(n−1) and many annular slants, whose slanting angles become steeper with increasing radius r. The difference step λ/(n−1) corresponds to a phase difference of 2π of light waves. Since light is waves, the difference of 2π makes no change of the wavefunctions. The m-th ring radius r m is defined as r m satisfies
φ( r )=−2 πm . (m=1, 2, 3, . . . ) (5)
A Fresnel lens is designed by dividing the surface of a refractive lens at the m-th ring radius and raising the edges to the common top level. The scope of thickness variations is λ/(n−1). The Frenel lens (b) of FIG. 3 is a half section of the Fresnel lens. If the starting refraction lens (a) is a flat-convex lens of a curvature radius R of Eq. (1), Eqs. (1), (4) and (5) give the m-th ring radius r m
r m ={2 mλR /( n− 1)} 1/2 . (m=1, 2, 3, . . . ). (6)
The Fresnel ring radii vm increase in proportion to roots of the order parameter m. Thus the interval r m −r m-1 decreases with increasing the order m.
r m −r m-1 ={2λ R/ ( n− 1)} 1/2 /{m 1/2 +( m− 1) 1/2 }. (7)
A Fresnel lens is composed of many annular rings. An annular ring consists of an oblique wall and a vertical wall. The oblique wall is here called an annular “slant” (slant in short). The vertical wall is called an annular “precipice” (precipice in brief). The first slant is the central convex part. The second annular slant is the next oblique annulus. Slants are defined in order. The first precipice is the first step r=r 1 . The m-th precipice is the m-th step. The m-th slant is an oblique part held between the (m−1)-th precipice and the m-th precipice. Eq. (7) denotes a radial width of the m-th slant. At the m-th ring (m≧2), the radial width of the slant is described by Eq. (7) and the height of the precipice is λ/(n−1). An oblique angle Y m of the m-th slant to the horizontal plane is
Y
m
=
{
λ
/
(
n
-
1
)
}
/
[
{
2
λ
R
/
(
n
-
1
)
}
1
/
2
/
{
m
1
/
2
+
(
m
-
1
)
/
2
}
]
=
{
λ
/
(
n
-
1
)
}
1
/
2
{
m
1
/
2
+
(
m
-
1
)
1
/
2
}
/
{
2
R
}
1
/
2
=
{
2
λ
R
/
(
n
-
1
)
}
1
/
2
[
{
m
1
/
2
+
(
m
-
1
)
1
/
2
}
/
2
]
/
R
.
(
8
)
Eq. (6) shows the dividend of Eq. (8) is an average radius <r m > of the m-th annular slant, where < . . . > means an average. An average oblique angle Y m of the m-th slant is
Y m =<r m >/R. (9)
The oblique angle of the slant coincides to the oblique angle Y=r/R at a radius r of the original refractive lens (Eq. (1)). It is a matter of course. The Fresnel lens (b) has the same oblique angles at every point as the base refractive lens (a). The refraction function in the Fresnel lens is the same as the refraction lens. Equality of the oblique angles has been confirmed for clarifying that the Fresnel lens has convergence power based upon the refraction function similar to the refractive lens.
A refractive lens has a large thickness variation. An aperture D and a focal length f require a refractive lens to have a large thickness variation (D/2) 2 /2(n−1)f from a refractive lens. Such a large required thickness variation prohibits us from thinning refractive lenses. Refractive lenses are heavy, thick and expensive.
On the contrary, a Fresnel lens has a small thickness variation λ/(n−1), which is the unit height of a precipice. λ/(n−1) is far smaller than (D/2) 2 /2(n−1)f. The small thickness variation enables Fresnel lenses to be thin and light. Resin molding allows us to produce cheap, light thin plastic Fresnel lenses at low cost.
A general expression of thickness distribution h(r) of a Fresnel lens which has the same convergency as a reference refraction-type lens having a continual thickness distribution d(r) is given by
h ( r )=mod { d ( r ),λ/( n− 1)}+ h 0 . (10)
Here h 0 is a base thickness of the lens, and d(r) is a continual thickness distribution of the reference refractive lens. The symbol, “mod {A, B}” means the rest of dividing A by B. Namely when A=sB+q for some integer s (0≦q<B), mod {A, B}=q. λ/(n−1) corresponds to one wavelength difference in a medium of a refractive index n. Instead of λ/(n−1), mλ/(n−1) (m; integer), which is m-times as large as λ/(n−1), is also available for the latter term in the mod bracket. The diffraction efficiency is the highest at m=1 (the first diffraction). Thus Eq. (10) employs λ/(n−1) as a divisor.
Here λ/(n−1) is the height of a precipice (or vertical height of a slant). The height h(r) of slants is determined by subtracting a multiple of λ/(n−1) (λ/(n−1), 2λ/(n−1), 3λ/(n−1), . . . ) from the slant height d(r) and keeping a height variation (h(r)-h o ) smaller than the precipice height λ/(n−1). The function h(r) determines the heights of concentric slants.
The slopes of the concentric slants are similar to the slope of the starting refraction-type lens (Ym=Y). A Fresnel lens has a convergence (or divergence) function only by refraction caused by the slopes of the concentric slants. Geometric optics can describe the convergence and lens function of the Fresnel lens. The Fresnel lens has advantages of lightness, inexpensiveness and low-cost (in the case of plastic lenses).
The Fresnel lens has a neutral character. In addition to refraction, the Fresnel lens has a diffraction function. Diffraction is an operation inherent to waves. It may sound strange that the Fresnel lens invites diffraction, but it is true. Both diffraction and refraction accompany a Fresnel lens. Diffraction can be explained by Heugence's principle. Waves starting from a point make concentric waves of a common phase. Propagating waves can be described as superpositions of concentric waves starting from the original points.
In the case of a refractive type lens, all the phases of the waves passing through the refractive lens are identical at any wavefronts. The converging point by diffraction coincides with the converging point by refraction. Thus diffraction is ignored in the calculation of the optics built by refractive lenses. However, it does not mean that refractive lenses are free from diffraction. Diffraction does exist in refractive lenses. But the result of diffraction coincides with the result of refraction. The diffraction must not be considered in refractive lenses.
In the case of a Fresnel lens having a sawtoothed section, refraction still dominates over diffraction. Individual parts are called elementary rings. An elementary ring consists of a slant which is a slanting circular plane and a precipice which is a vertical wall. Slants of elementary rings are important, because the slanting angles of the slants rule refraction. Refraction is dominant owing to the wide slants. The sawtoothed shape (slant and precipice) induces diffraction also in a Fresnel lens. What results from diffraction? Waves originating from neighboring edges of the elementary rings converge at a point where the distance from single neighboring edges differs by one wavelength unit (λ/(n−1)). This is the first diffraction. Since a pair of the neighboring rings have separated by a precipice of λ/(n−1), the rays emitted from corresponding spots of the two slants converge at a focus with one wavelength difference. Thus the focus of reflection is the first-diffraction focus at the same time. In a Fresnel lens, the foci of refraction and the first-diffraction are common. Namely a Fresnel lens makes an image by refraction at a focus and produce the same image by the first-diffraction at the same focus. Of course, higher order diffraction exists. The higher order diffraction makes images different from the images by refraction.
Fresnel lenses have no serious problem, because the focus of the first-diffraction image is the same as the focus of the refraction image. However, the image by a Fresnel lens is not entirely equal to the image by a refraction-type lens. The Fresnel lens causes 0th-order, +2nd-order, +3th-order, . . . diffractions and −1st-order, −2nd-order, . . . diffractions in addition to the first-order diffraction. Only the first-order diffraction coincides with the result of refraction. Extra diffractions, 0th-order, +2nd-order, +3th-order, . . . diffractions and −1st-order, −2nd-order, . . . diffractions, make different images at different converging points. The 0-th order diffraction has an infinite long focal distance. The ±m-th order diffractions have converging points at ±f/m, where f is the focal distance of the first-order diffraction and m is an integer. The plus sign (+) means convergence and the minus sign (−) means divergence. Thus a Fresnel lens makes images of ±m-th order diffractions at points distanced from the first-order diffraction focus. The power of the extra order diffractions is not large at the first-order focus. Therefore Fresnel lenses do not take diffraction into account. But diffraction exists. Diffraction disperses power of waves to multipoints (±f/m) lying on the light axis in the Fresnel lenses.
Fresnel lenses have advantages of inexpensiveness, thinness and lightness. However Fresnel lenses have two serious drawbacks. One is fixation of a wavelength of object (a work piece) light. The height of precipices is λ/(n−1). A Fresnel lens is applicable only to one wavelength λ, which is equal to (n−1)P, where P is the height of a precipice. For example, when the wavelength is 0.5 μm and the refractive index is n=1.5, the height of a precipice is uniquely determined to be P=1 μm. The Fresnel lens designed for a laser beam with a 1 μm long wavelength can only be used for monochromatic light with a 1 μm wavelength. The Fresnel lens exhibits the designed focal length and the designed convergence only for 1 μm wavelength light. The Fresnel lens is inapplicable to extra light except the designed wavelength. Fresnel lenses have a strong wavelength-dependence. This is a drawback of Fresnel lenses.
Strictly speaking, the refraction of a Fresnel lens is not fully identical to the refraction of a refraction-type lens. At a precipice, the Fresnel lens changes the thickness suddenly by λ/(n−1). The refraction function of a Fresnel lens is similar to that of a refractive-type in the rays parallel to the optical axis but is different from in the rays which are not parallel to the axis. The Fresnel lens is inferior to the refraction lens in the non-parallel rays. This is, however, not a significant problem.
Another problem of Fresnel lenses is the difficulty of shaping because of many concentric rings with circular precipices and circular slants. Plastic Fresnel lenses can be cheaply produced by molding. However, in the case of hard materials, e.g., quartz, molding is unfit to make a lens. A quartz Fresnel lens should be made by cutting and grinding a quartz disc. It is difficult to cut exactly multi-concentric slants and precipices. Grinding is also difficult. Thus Fresnel lenses made of glass or quartz are not inexpensive.
Thus modified Fresnel lenses have been contrived by quantizing continual slants into a discrete stepwise structure, for example, two steps, four steps, eight steps, sixteen steps, . . . , or g steps (g: division number, g=2 b ; b: integer) for facilitating production. Fresnel lenses and stepped Fresnel lenses are called thickness modulating diffractive lenses for discriminating other types of diffractive lenses, which will be described later. For example, sixteen step modified Fresnel lenses (g=16, b=4) are designed by dividing a circular slant with a height λ/(n−1) of a reference Fresnel lens into sixteen steps. Here a step has a height λ/16(n−1). A discrete surface of the g step modified Fresnel lens is described by a surface thickness function h g (r)
h g ( r )={λ/ g ( n f −1)}· int[g ·mod {( n− 1) d ( r )/λ,1 }]+h 0 . (11)
Here g is a division number, g of h g is a suffix denoting the division number, d(r) is a thickness distribution of the reference refractive lens, n is a refractive index of the reference refractive lens, n f is a refractive index of the stepped Fresnel lens and h 0 is a base thickness. The symbol int{ . . . } means an integer obtained by eliminating the decimal fraction of the value bracketed { . . . }. Namely int{X} is the maximum integer which does not exceed X. For example, when the division number is four (g=4, b=2), a 4-step modulated Fresnel lens is described by
h 4 ( r )={λ/4( n f −1)} int[ 4 mod {( n− 1) d ( r )/λ,1 }]+h 0 , (12)
where the division number is 4, d(r) is a thickness distribution of the reference refractive lens, n is a refractive index of the reference refractive lens, n f is a refractive index of the stepped Fresnel lens and h 0 is a base thickness.
When the division number is eight (g=8, b=3), a 8-step modulated Fresnel lens is defined by
h g ( r )={λ/8( n f −1)} int[ 8 mod {( n− 1) d ( r )/λ,1 }]+h 0 , (13)
where the division number is 8, d(r) is a thickness distribution of the reference refractive lens, n is a refractive index of the reference refractive lens, n f is a refractive index of the stepped Fresnel lens and h 0 is a base thickness.
When the division number is sixteen (g=16, b=4), a 16-step modulated Fresnel lens is defined by
h 16 ( r )={λ/16( n f −1)} int[ 16 mod {( n− 1) d ( r )/λ,1 }]+h 0 , (14)
where the division number is 16, d(r) is a thickness distribution of the reference refractive lens, n is a refractive index of the reference refractive lens, n f is a refractive index of the stepped Fresnel lens and h 0 is a base thickness.
The lenses designed by quantizing continual circular slants of a Fresnel lens into discrete steps are called “quantized-step lenses”.
When the division number g is large enough, for example, g=16 (b=4) or g=256 (b=8), the stepped surface of the diffraction lens is similar to the original Fresnel lens. Somebody would think that the rays going into the lens should be refracted under the law of refraction. But it is wrong. The rays obeying the law of refraction do not converge and disperse in vain without making any image. Refraction is insignificant in the diffraction lens. Instead of refracted rays, diffraction converges the rays at the focus.
It is difficult to produce diffraction lenses of high division number g. Production of plenty of annular slants and precipices by grinding rigid materials incurs high cost. The production cost raises with increasing division number g.
The most inexpensive choice is to adopt the simplest diffractive lens of a division number 2 (g=2, b=1). The lens has only two kinds of heights or thicknesses. Since the lens has only two kinds of steps, the simplest lens is called a binary lens. The steps are all vertical to the axis. Convergency depends only upon diffraction. Refraction has no convergency in the binary lens. The thickness h 2 (r) of a binary lens is given by
h 2 ( r )={λ/2( n f −1)} int[ 2 mod {( n− 1) d ( r )/λ,1}]+ h 0 . (15)
FIG. 3( c ) denotes a half section of a binary lens. Comparison of FIG. 3( b ) and FIG. 3( c ) clarifies how to make a binary lens ( c ) from an original Fresnel lens ( b ). Slants of ( b ) are divided into two parts by comparing the heights of slants with a half wavelength depth λ/2(n−1). Parts higher than the half wavelength height are allocated to top annuli. Other parts lower than the half wavelength height are allotted to bottom annuli. The difference between the top and the bottom annuli is λ/(n−1). The binary surface is a rough approximation of the Fresnel lens (b). The binary lens converges incident rays by only diffraction. Refraction plays no role. Diffraction includes many orders. Only the plus first order (+1) diffraction converges the incident ray at the predetermined focus. Other orders of diffraction converge the rays at different points or diverge the rays.
The lens which is produced by quantizing the slants of a Fresnel lens by 2 b (=g) steps of microannuli having planes vertical to the beam axis is called a diffraction lens. The lens converges rays by diffraction besides refraction. The rate of diffraction to refraction increases as the step number g=2 b decrease. Neighboring annuli are connected by microprecipices. The number of microannuli of the diffraction lens is 2 b times as large as the number of the slants of the Fresnel lens. All the annuli have parallel flat planes orthogonal to the beam axis. However, the diffraction is not increased with the increase of the step number g. Convergency by diffraction is not changed by the decrease of the step number g. Refraction decreases as the decrement of the step number g. Here, diffraction lenses include quantized-step lenses and Fresnel lenses. The Fresnel lens, which converges rays by both refraction and diffraction, has neutral properties.
As explained before, the diffraction lens has an eigen wavelength λ, which is determined by the height of the steps of λ/(n−1). The strong wavelength dependence is a weak point for the diffraction lens. The diffraction lens has not a full converging function for wavelengths other than the eigen wavelength.
What is caused by the use of non-eigen wavelengths in diffraction-type lenses? What occurs when the incident wavelength is changed with maintaining the step height, step width and step number in a diffraction lens? Hitherto the wavelength and the focal length have been denoted as λ and f, which take constant values. From now wavelengths and focal lengths are variable parameters. To discern the constant ones, variable wavelengths and variable focal lengths are denoted by Λ and F in capital letter. The boundaries of annular slants are given by Eq. (6).
r m ={2 mλR/ ( n− 1)} 1/2 . (m=1, 2, 3, . . . ) (6)
The difference between the distance from the focus F to the m-th precipice (r=r m ) and the distance from the focus F to the (m−1)-th precipice (r=r m-1 ) is Λ.
Λ=( F 2 +r m 2 ) 1/2 −( F 2 +r m-1 2 ) 1/2 . (16)
Since r m , r m-1 <<Λ, Eq. (16) is approximated to
Λ= r m 2 /2 F−r m-1 2 /2 F. (17)
Substitution of Eq. (6) into Eq. (17) produces
2
F
Λ
=
{
2
m
λ
R
/
(
n
-
1
)
}
-
{
2
(
m
-
1
)
λ
R
/
(
n
-
1
)
}
=
2
λ
R
/
(
n
-
1
)
.
(
18
)
The lens has the standard focal length f (f=R/(n−1)) for the standard wavelength λ as aforementioned. Eq. (18) is rewritten to
FΛ=fλ. (19)
The product of a wavelength Λ and a temporal focal point F is constant. This simple relation is obtained from the requirement that the light path difference between the rays emitting from neighboring slants should be Λ. Refraction is not taken into account for deriving Eq. (19). Diffraction enables the lens to converge non-standard wavelength (Λ≠λ) rays at another focal point F (F≠f) different from the standard focus f. The temporal focal points F is inversely proportional to the wavelength Λ. However convergency is poor for non-standard wavelength Λ.
The diffraction type lens has large power of allocations to non-first order diffraction. The higher order diffraction gives the diffraction lens multifocal points (±F/m). The multifoci (±F/m) align on the central light axis before and after the lens. When the temporary wavelength Λ is near to the standard wavelength λ, the first-order diffraction is dominant. The temporary first order focal length F is called the focal length of a set of the lens and the wavelength. “Wavelength dispersion” is defined as a ratio (dF/dΛ) of a focal length change dF to a wavelength change dΛ. In the refractive-type lens, the wavelength dispersion (dF/dΛ) is very small. Eq. (19) demonstrates that diffraction type lenses have very large wavelength dispersion unlike refractive type lenses. Differentiation of Eq. (19) of the diffraction-type lens gives the wavelength dispersion,
dF/dΛ=−fλ/Λ 2 ·(Diffraction lens) (20)
This is an expression of the wavelength dispersion of diffraction lenses. The wavelength dispersion Eq. (19) is always negative. Diffraction type lenses have large, negative wavelength dispersion. Since Λ is as large as λ, the dispersion (dF/dΛ) is nearly equal to −f/λ. This means big negative wavelength dispersion. On the contrary, refractive-type lenses have very small dispersion which originates from the refractive index dispersion dn/dλ. The parameter dn/dλ is negative and small in refractive lenses. FIG. 4 demonstrates focal length variations caused by a wavelength change for a refractive lens and a diffractive lens. The wavelength change scarcely induces a focal length change in the refraction lens (left figure of FIG. 4 ). On the contrary, the diffractive lens has a wide change of focal points caused by the wavelength change (Right figure of FIG. 4 ).
The wavelength dispersion of the refractive lens has been given by Eq. (3)
( df/dλ )=− f 2 ( dn/dλ )/ R ·(Refractive lens) (3)
Material dispersion (dn/dλ), which is a small, negative value, gives very small positive wavelength dispersion to refractive type lenses. Diffraction lenses have negative wavelength dispersion far larger than refraction lenses. The large dispersion originates from the fact that the standard wavelength is fixed by the precipice height P=λ/(n−1).
Properties of an ultrashort pulse laser are considered. Since a pulse width is femtoseconds (10 −15 s) to picoseconds (10 −12 s), the pulse is named here “ultrashort”. The word “short” means not a short wavelength but a short pulse width Δt. Since the pulse width is farther shorter than nanosecond pulses, the pulse is named here “ultrashort”. Sometimes the ultrashort pulse is called a femtopulse in this description, since the time width is an order of femtoseconds (10 −15 s). Monochromacity is one of the important features of laser light. Monochromacity means that the light only consists of a single wavelength. Continual wave lasers (CW) or long pulse lasers have monochromacity. However, in the case of the ultrashort pulse laser light, the uncertainty principle obscures the energy of an ultrashort pulse. The energy of light is given by hν=hc/λ. Since the pulse width is very short, the energy does not take a definite value. Thus the wavelength has uncertainty. Wavelengths of an ultrashort pulse disperse into a definite range around a standard wavelength λ. Energy dispersion or wavelength dispersion is a defect for lasers, since energy fluctuation contradicts the laser-inherent monochromacity. This is a defect of a femtosecond pulse laser. This invention, however, tries to make the best use of the wavelength fluctuation of the femotosecond pulse for prolonging a focal depth. The uncertainty principle says that the product of time fluctuation Δt and energy fluctuation ΔE or the product of momentum fluctuation Δp and displacement fluctuation Δx is not less than Plank's constant h. Energy E and time t are “conjugate” physical variables. Displacement x and momentum p are conjugate physical variables. The product of the fluctuations of conjugate variables is not less than h. The uncertainty principle is expressed by
ΔEΔt≧h, (21)
and
ΔxΔp≧h. (22)
Heisenberg first advocated the principle. Δ means a fluctuation of physical variables. The word “fluctuation” has been defined in various ways. A root-mean-square RMS, a standard deviation σ and an absolute value deviation average (<|x−m|>) are examples of fluctuation. Numerical factors are significant for this invention to obtain exact estimation. Thus fluctuation should be precisely defined for enabling us to calculate exact numerical factors. What is important is the product ΔtΔE of the time fluctuation Δt and the energy fluctuation ΔE. Stochastics teaches us that the distributions which minimize the fluctuation product are Gaussian distributions for both time and energy. Thus the relation between numerical coefficients of energy and time fluctuations is considered upon the assumption of gaussian distributions for both time and energy. The expression of energy of light is accompanied by the plank constant h. For simplifying expressions, angular frequency ω is adopted in stead of energy E. The angular frequency ω is related to energy by an equation hω=2πE. A Gaussian function can be expressed in a simple form by a standard deviation. The standard deviation of angular frequency fluctuation is denoted by ε. The standard deviation of time fluctuation is denoted by η. It is assumed that both time and angular frequency fluctuations take Gaussian distributions.
A normalized Gaussian angular frequency distribution is written as,
(2πε 2 ) −1/2 exp(−ω 2 /2ε 2 ). (23)
Here a “normalized” function g(ω) means that the integration of the variable in a full range is 1. Namely ∫g(ω)dω=1.
A normalized Gaussian time distribution is expresses by
(2πη 2 ) −1/2 exp(−t 2 /2η 2 ). (24)
Fluctuation distributions of conjugate variables are reversibly connected by Fourier transformations. Irrespective of the assumption of the Gaussian distributions, a Fourier transformation of the angular distribution is the time distribution. A Fourier transformation of the time distribution is the angular distribution. Fourier-transforming of Eq. (23) gives
(2π) −1/2 (2πε 2 ) −1/2 ∫exp(−ω 2 /2ε 2 )exp(− jωt ) dω= (2π) −1/2 ∫exp(− t 2 ε 2 /2). (25)
This expression denotes the time dependent distribution of an ultrashort pulse. Eq. (24) and Eq. (25) should represent an identical time distribution.
ε=1/η. (26)
The result teaches us that the time fluctuation and angular frequency fluctuation obeying Gaussian distributions give a product of the time and angular frequency standard deviations ε and η which is always equal to 1 (εη=1). Non-gaussian distribution-obeying time and angular frequency fluctuations give a product larger than 1 (εη>1). General distributions including Gaussian and non-Gaussian give εη≧1. The Fourier transformation calculation Eq. (25) has been carried out for clarifying that the numerical factor of the product is 1.
The root-mean-square (<ω 2 >) of angular frequency distribution is named an angular frequency fluctuation. The average of ω 2 is equal to ε 2 . The root of the average of ω 2 is equal to ε. Thus the root-mean-square of the angular frequency ω is equal to the standard deviation ε.
The root-mean-square (<t 2 >) of pulse time distribution is named a time fluctuation. The average of t 2 is equal to η 2 . The root of the average of t 2 is equal to η. Thus the root-mean-square of the time t is equal to the standard deviation η.
The standard deviation σ is the most popular representation of fluctuation of stochastic variables. However, the standard deviation is not always a parameter which is favorable for measurements.
The standard deviation cannot be directly determined from the measured spectrum. Thus a full width at half maximum (FWHM) is employed for representing fluctuation instead of the standard deviation σ.
The FWHM is defined as a full width of a peak at the height of half of the maximum. The FWHM can be directly measured from a spectrum graph unlike the standard deviation σ.
If object (a work piece) stochastic variables follows a Gaussian distribution, a clear relation holds between the FWHM and the standard deviation σ. Eq. (23) is a distribution function of angular frequencies of wavefunction of light. Actual experiments measure squares of wavefunctions. An actual measured angular frequency distribution function is given by squaring Eq. (23). Squaring replaces “2” at the denominator in exp( . . . ) by “1”. The FWHM of the angular frequencies is denoted by Δω. The half width is Δω/2. Substituting Δω/2 into the angular frequency distribution function squared Eq. (23) should make 1/2(=0.5) owing to the definition of the FWHM.
exp(−(Δω/2) 2 /ε 2 )=1/2 (27)
Since the maximum of the lefthand term is 1, the righthand term 1/2 means a half of the maximum. Natural logarithm having “e” as a bottom is described as “ln”. Natural logarithms of both terms show a relation of,
Δω=2(ln 2) 1/2 ε. (28)
The FWHM (full width at half maximum) Δω is a value of the same order as the standard deviation σ. But Δω and σ are not rigorously identical. The ratio of dividing Δω by ε is 2(ln) 1/2 . In the present description, numerical constants 2(ln 2) 1/2 or 2 ln 2 often appear. The constants are born by replacing the standard deviation ε by the FWHM Δω in the Gaussian function. 2 ln 2=1.386 and 2(ln 2) 1/2 =1.665. Approximate calculations would deem Δω identical to ε by neglecting the numerical factors. But the present invention aims at obtaining the exact solution of designing optical devices and tries to calculate exactly the numerical constants. However, the results are relied upon the assumption of the Gaussian distribution. Actual distribution is not exactly gaussian. Thus the relation between Δω and ε may deviate from the ratio of 2(ln 2) −1/2 in actual ultrashort (femtosecond) laser pulses.
Similarly, Δt denotes a full width of half maximum (FWHM) of time of a femtosecond pulse. Eq. (24) shows a time-dependent distribution of an ultrashort pulse. Measurable distribution is given by a square of Eq. (24). The definition of the FWHM gives 1/2 to the square of Eq. (24) at t=Δt/2.
exp(−(Δ t/ 2) 2 /η 2 )=1/2. (29)
Then
Δ t= 2(ln 2) 1/2 η. (30)
If the pulse duration time (pulse widths) follows an ideal Gaussian distribution, εη=1, where ε is the standard deviation of angular frequencies and η is the standard deviation of pulse widths (duration time). Usual distributions other than the Gaussian function give εη≧1.
Eq. (28) and Eq. (30) establish an inequality
ΔωΔt≧4 ln 2. (31)
The pulse width FWHM ΔT and the angular frequency FWHM Δω are connected by the above uncertainty rule. In the case of holding the equality both the frequency and the pulse width have Gaussian distributions. Attention should be paid that the symbol “Δ” which denotes not a standard deviation but a full width at half maximum (FWHM).
What is important is the minimum fluctuation of pulse widths and frequencies. Thus the minimum fluctuation is considered by assuming εη=1.
(At the minimum of fluctuations)ΔωΔt=4 ln 2. (32)
Assuming that the pulse width Δt has been known, Eq. (32) means that the minimum of the product of the frequency fluctuation Δω and the pulse width Δt should be 4 ln 2=2.77.
ω=2πν=2 πc/Λ, (33)
where ν is the frequency of the laser pulse light, c is a light velocity (c=3×10 8 m/s in vacuum or air) and Λ is the wavelength of the laser light. Differentiation of Eq. (33) makes a differential expression,
dω=− 2 πcdΛ/Λ 2 , (34)
where dω is an infinitesimal change of ω and dΛ is an infinitesimal change of Λ. The ratio of fluctuations is equal to the ratio of the infinitesimal changes. The fluctuations satisfy the ration determined by Eq. (33). The FWHMs are ones of fluctuations, which are defined by positive values. The FWHM of the wavelength fluctuation is denoted by ΔΛ and the FWHM of pulse width fluctuation is denoted by Δt. Inequality (31) and Eq. (34) yield an inequality determining the minimum of ΔΛ
ΔΛ≧2(ln 2)Λ 2 /cπΔt. (35)
The narrower the pulse widths Δt of laser light are, the wider the fluctuation of wavelengths increase. For example, when the pulse width is 100 fs and the wavelength is 800 nm, namely Δt=100 fs=10 −13 s and Λ=800 nm=0.8 μm=0.8×10 −5 m. The minimum ΔΛ min of wavelength fluctuation FWHM is
ΔΛ min =0.0094 μm=9.4 nm. (36)
The example shows the occurrence of a big wavelength fluctuation for ultrashort pulses. The big wavelength fluctuation is an inherent drawback of ultrashort pulses.
The inventors of the present invention tried to exploit the inherent drawback by contraries. The present invention makes the best use of the double drawbacks of diffraction lenses and ultrashort pulses for obtaining a long focal thickness. The present invention converts the drawbacks into advantages.
In a diffraction-type lens, the change of an effective wavelength Λ induces a large change of the focal length in inverse proportion to the wavelength Λ, as clarified before. Hence,
Δ F=ΔΛF/Λ≧ 2(ln 2)Λ F/cπΔt. (37)
Since λf=ΛF, the effective wavelength Λ and the effective focal length F are replaced by the standard wavelength λ and the standard focal length f in Inequality (37).
Δ F≧ 2(ln 2)λ f/cπΔt. (38)
Inequality (38) denotes the fact that a diffraction lens causes a focal length change ΔF for an ultrashort pulse (Δt). The focal length change ΔF is inversely proportional to the pulse width Δt. A shorter pulse width causes a larger focal length change.
Another important parameter is a focal depth. The focal depth is defined as a length of the region near beamwaist whose sectional area is smaller than four times as large as the beamwaist section. FIG. 2 shows convergence of parallel laser beam by a lens. The beamwaist is a point having the minimum section of rays. The beamwaist is produced at the focal point. The periphery of a beam is defined as an envelope of the points having power density of e −2 times as small as that of the center. The radius of the beamwaist is a distance from the center to a point at which the power density falls to e −2 times that of the center. The radius of a parallel incidence laser beam following the Gaussian power density distribution is denoted by w o . The laser beam radius w o is a large value of an order of millimeters. The parallel laser beam of a wavelength λ is converged by the lens with a focal length f. The beamwaist is produced at the focus of the lens. Ideal Gaussian power distribution gives the beamwaist a radius w 1 ,
w 1 =λf/πw 0 . (39)
A virtual, imaginary, ideal parallel light beam without diffraction would perfectly converged to a point of a 0 diameter (w 1 =0) at a focus by a lens. But diffraction always accompanies actual laser beams. The diffraction gives a definite size w 1 to the converged beam at the focus. Thus the section of a definite size at the focus is called a beamwaist. The radii w o and w 1 are defined as the distances from the beam center to the points at which the power density decreases to e −2 times that of the central density in the case of Gaussian distribution beams. The incident beam radius w o is slightly different from the incident beam width FWHM Δi. The ratio Δi/w 0 should be determined. The incident beam width FWHM Δi is twice that of the distance r=Δ which gives half power (0.5=e −0.69 ) of the beam center. The incident beam radius w 0 is the distance r=w 0 which gives e −2 times as small as that of the beam center. Namely the gaussian function is expressed by exp(−2(r/w 0 ) 2 ). For r=Δi/2, 0.5=exp(−2(Δi/2w 0 ) 2 ), then 0.69=2(Δi/2w 0 ) 2 .
Δ i/w 0 =2×(0.69/2) 0.5 =(21 n 2) 0.5 (40)
The FWHM of the incident laser beam is Δi. The incident beam radius w 0 is w 0 =Δi/(2 ln 2) 0.5 . Substituting (40) into Eq. (39) gives the beamwaist w 1 of the beam converged by the lens with a f focal length,
w 1 =(21 n 2) 0.5 λf/πΔi. (41)
The focal depth z of a refractive-type lens, which has a focal length f, should be defined. There are some different definitions of the focal depth. A virtual cylinder is assumed to have a radius equal to the beamwaist w 1 . The rays converged by a lens have an envelope (fire lines) of twin cones. The cones have two crossing circles with the virtual cylinder before and after the focus. The distance between the front crossing circle and the rear crossing circle is defined as the focal depth z.
FIG. 2 denotes the definition of the focal depth. A laser emits a parallel beam with a radius w 0 . A lens converges the laser beam. The converged beam forms a beamwaist of a radius w 1 at the focus. The beamwaist radius w 1 is given by Eq. (39) for a Gaussian laser beam. But the beamwaist radius w 1 is larger than the value of Eq. (39) for a non-Gaussian beam. In FIG. 2 , the inclination angle of fire lens of beams converged by the lens is w 0 /f, because the incident beam radius is w 0 . Virtual sections having a radius equal to the diameter 2w 1 of the beamswaist are imagined within the fire lens. A cylinder having both virtual sections of the 2w 1 radius are assumed in the fire lines. The length of the assumed cylinder is the focal depth δz. Since the radius is 2w 1 and the focal depth δz is equal to a quotient 2w 1 f/w 0 of dividing 2w 1 by w 0 /f. Here “δ” does not mean differentiation. δ is attached to z for denoting the focal depth, since the cyclindrical range in the focal depth is a z-direction restricted region having energy density larger than a definite value. The sign “δ” should be clearly discerned from the other sign “Δ”, which means an FWHM (Full Width at Half Marium)
δ
z
=
2
w
1
/
(
wo
/
f
)
=
2
λ
f
2
/
π
wo
2
=
(
4
ln
2
)
λ
f
2
/
π
(
Δ
i
)
2
(
42
)
Hereafter the central idea of the present invention is described. The focal depth δz of Eq. (42) derives from assumptions of the Gaussian laser beam and a refractive type converging lens. Eq. (42) determines an ideal relation between Δi and δz. If the incident laser beam is a non-Gaussian beam, the beamwaist w 1 becomes larger than w 1 of Eq. (39). δz takes a longer depth than the Gaussian incident beam. When a diffractive-type lens is employed, the focal depth is represented by Eq. (42) as well as a refractive-type lens.
Hitherto it has been explained that diffractive lenses bear large wavelength dispersion where in a way that a temporary focal length F changes in inverse proportion to a temporary wavelength Λ when Λ deviates from the standard wavelength λ. It has been also clarified that an ultrashort pulse includes a variety of wavelengths of light waves due to the ultrashortness of a pulse width. Therefore, an ultrashort laser pulse includes elementary waves of various wavelengths which cause a large focal length variation ΔF. Usual optical apparatuses dislike the focal length variation ΔF, which would disperse laser power.
The present invention tries to make the best use of the focal length variation ΔF. When the focal length ΔF changes, the focal point at which a parallel beam converges, varies, as shown in FIG. 4 . Multiwavelength induces multifocus. The scope of focal points is denoted by Δf. Since the focal depth displaces with the focus, the effective focal depth is increased by the axial change of the focal points (multifocal points). At a temporary wavelength Λ having a focal length F, the rays converge at positions from −δz/2+F to +δz/2+F on the axis. The focal length Λ itself varies in a range from −ΔF/2+f to +ΔF/2+f. As a whole, rays converge on the axis in a range from −δz/2−ΔF/2+f to +δz/2+ΔF/2+f. The focal length is prolonged from δz to δz+ΔF. The additional extra focal length ΔF is the gist of the present invention.
Among the factors, δz is the inherent focal length which accompanies also refraction-type lenses. The extra focal length ΔF, however, derives from the coupling of the diffractive-type lens and the ultrashort pulse. ΔF enlarges the focal length. However, too small ΔF is insignificant, because the focal length is not so much prolonged. If ΔF is longer than δz, the substantial focal length is increased by more than two times as long as the inherent one δz. If ΔF is far larger than δz, the actual focal length is raised by several times as long as δz. If the ratio ΔF/δz is denoted by q, the focal length is prolonged up to (q+1) times as long as δz. A Z-parameter Zp is defined to be,
Zp=δz/ΔF. (43)
If Zp is less than 1 (Zp≦1), the focal length is multiplied by a sum (Zp −1 +1) of the reciprocal of Zp and 1. Assuming that ΔF takes the minimum value for a given Δt, Inequality (38) and Eqs. (42) and (43) give the Z-parameter an expression,
Zp= 2 cΔtf/Δi 2 . (44)
The Z parameter Zp is a value obtained by dividing twice product of the FWHM pulse width Δt, the focal length f and the light velocity c by a square of the incident beam width Δi. The present invention requires Zp≦1 for deepening the focal depth effectively. Attention should be paid the fact that Zp does not contain the wavelength λ. The focal depth is used to increase in proportion to the wavelength λ. However, Zp contains no wavelength. The Z parameter Zp is not a focal depth itself. Zp is a quotient of the inherent focal depth divided by the extension (fluctuation) of the focal length. In diffractive lenses, the focal length f is in proportion to the wavelength Λ. The focal depth is similar to the focal length in the wavelength dependence. Thus Zp does not contain the wavelength, since the wavelength dependence cancel each other. The condition Zp≦1 can be explicitly rewritten into fΔt/Δi 2 ≦1.67×10 −9 m −1 s. The present invention restricts that FWHM pulse width Δt should be less than 20 ps. The maximum pulse width (20 ps) gives an inequality f/Δi 2 ≦83 m −1 . The inequality imposes a rigorous requirement upon the FWHM incident beam width Δi. Even if f=50 mm, Δi≧24 mm. This means a very large diameter of a laser beam. The laser apparatus which can produce such a large diameter beam is very large and much expensive. When f=100 mm and Δt=1 ps, the incident beam width should be larger than 7.7 mm (Δi≧7.7 mm). Zp≦1 can be deemed to define the minimum of the incident beam width Δi. A larger beam Δi, a shorter f and shorter pulse width Δt give a lower Zp.
Shortening the focal length f is one contrivance for lowering the Z parameter Zp in diffraction lenses. It requires an increase of the number of annular slants and annular precipices. Narrowing the pulse width Δt is another contrivance for lowering the Z parameter Zp in diffraction lenses. In this case, the time power density should be intensified for avoiding shortage of effective power density.
The present invention restricts the FWHM pulse width Δt below 20 ps (Δt≦20 ps, ps=10 −12 s). Short pulses, for example, 100 ft and 50 ft (ft=10 −15 s), can reduce the Z parameter Zp. An alternative is to widen the incident laser beam FWHM width Δi. The present invention can be interpreted to be a guide for restricting the minimum of the incident laser beam FWHM width Δi. The Z parameter Zp includes three independent parameters. Regulating three parameters can give Zp a value lower than 1.
Zp≦1. (45)
The above procedure teaches us that a quotient of the focal depth z divided by Zp gives the focal length fluctuation, which is an effective increase of the focal depth.
The Z-parameter is a positive value. Thus
0<Zp≦1. (46)
The range is suitable for Zp.
The motivation for defining a range of Zp between 0 and 1 appears for the purpose of restricting spatial broadening of the pulse in a definite region. When the spatial broadening is insignificant, the restriction imposed upon Zp is a range from 0 to 1 given by inequality (46).
In the refraction lens, the optical length of a near-axis ray running on the axis to the focus is equal to the optical length of a far-axis ray running at the periphery to the focus. Thus there is no delay time between the near-axis ray and the far-axis ray in the refractive lens. On the contrary, there are optical path differences between the near-axis ray and the far-axis ray. Since the thickness is common for the center and the periphery, the far-axis ray has a longer optical path than the near-axis ray in the diffraction lens. The optical path length of the nearest-axis ray is f. The optical path length of the farthest-axis ray is (f 2 +r 2 ) 1/2 , where r is a radial coordinate of the farthest axis ray. The difference of the optical path lengths between the nearest-axis rays and the farthest-axis rays is
( f 2 +r 2 ) 1/2 −f=r 2 /2 f. (47)
Delay time τ of the farthest-axis ray to the nearest-axis ray is obtained by dividing the path difference by the light velocity c,
τ= r 2 /2 fc. (48)
The width (FWHM) of the incident laser beam shooting the lens is Δi. The farthest-axis ray has a radius coordinate r=Δi/2. Substitution of r=Δi/2 to Eq. (48) gives a relation between the delay time τ and the incident beam width Δi.
τ=Δi 2 /2 fc. (49)
The effective pulse time width at the focus is a sum of the incident pulse width Δt and the time delay τ. For suppressing spatial dispersion of pulses, the farthest/nearest delay time Δτ should be shorter than the inherent pulse width Δt. Thus
Δτ/Δ t≦ 1. (50)
From Eq. (44) and Eq. (49),
Δτ/Δ t=Δi 2 /8 fc/Δt= 1/4 Zp= 0.25/ Zp. (51)
Inequality (50), which is a condition that the farthest/nearest delay Δτ should be smaller than the pulse width Δt, would determine the scope of the Z-parameter.
Zp≧0.25. (52)
Inequalities (46) and (52) determine a preferable range of the Z-parameter Zp.
0.25≦Zp≦1. (53)
However, 0.25 is not an absolute lower limit for Zp. In many cases, spatial broadening of laser pulses is allowable. Thus the lower limit is extended to 0. A preferable range of Zp is 0 to 1. (0<Zp≦1)
Here a question may happen. Does the delay time Δτ between the axis-farthest ray and the axis-nearest ray act to reduce the power fluctuation by counting Δτ in Δt? The axis-farthest ray and the axis-nearest ray have different optical paths. Thus the uncertainty principle is not held between the axis-farthest ray and the axis-nearest ray. Δτ is not counted in Δt. Δτ has no function of reducing the power fluctuation.
The sawtoothed-sectioned lens has been described as a diffraction-type lens. Physical shape of repeating slanting edges like saw teeth induces diffraction in the lens. In stead of forming the sawtoothed surfaces with concircular slants and precipices, saw-like modulation of refractive indices n(r) can cause diffraction. Another diffraction type-lens is made by modulating spatial distribution of refractive indices and keeping the thickness constant. This is named a refractive-index-modulating lens of diffraction type. This is a novel lens. The refractive-index-modulating lens is different from the thickness-modulating (sawtoothed lens) lens. The refractive-index-modulating lens induces diffraction by the repeated variation of the refractive indices as a function of radius r. Although the new lens has no sawtoothed, edged structure, the refractive-index modulating lens should not be confused with the refractive-type lens which refracts rays by changing smoothly the thickness.
The starting function is a thickness function d(r) of a thickness-modulation refractive-type lens. The phase of a ray which passes at a radius r delays by 2π(n−1)d(r)/λ from the axial ray (r=0), where n is the constant refractive index of the corresponding refractive lens.
The shape-dependent delay function should be replaced by a refractive index variation function n(r) for designing a refractive index-modulation lens. The thickness is a constant which is denoted by d f . The thickness variable is denoted by n f (r). The suffix “f” should not be confused with the focal length. The replacement equation is given by
n f ( r )−1=( n− 1) d ( r )/ d f . (54)
The n f (r) means that a refractive-index modulating lens, which is identical to the thickness-varying refractive lens, can be designed by changing the refractive index n as a function of r. In Eq. (54), d(r) and n f (r) are continual functions with regard to r. The refractive-index modulating lens determined by n f (r) is still a refractive-type lens without causing diffraction. The continual function d(r) should further be divided into sets of effective concentric slants and precipices as changes of refractive indices for producing a refractive-index modulating diffraction lens. A step of the change of (n−1)d(r) is λ. The continual n f (r) of Eq. (54) should be rewritten into a discontinual n f (r) function.
n f ( r )=mod {( n− 1) d ( r ),λ}/ d f +n 0 . (55)
Here d(r) and n are a thickness and a refractive index of the starting refractive-type lens respectively. In mod { . . . } of Eq. (55), d(r) is a r-dependent function but n is a constant. In Eq. (55), d f is the thickness (constant) and n o is a base refractive index of the object (a work piece) refractive-index modulating diffraction-type lens.
An Eq. (55) defining lens, which has flat surfaces and quasi-periodically varying refractive indices, is also a diffractive-type lens. It may sound quaint to call the refractive index modulating lens as a diffractive-type lens, because the lens makes use of only refraction. At crossing points of rays obeying Snell's law, rays having light path difference of a multiple of a wavelength meet and converge partially. At the converging points the rays refracted at different annular refractive index modulating regions have wavelength differences of just multiples of the wavelength. Rays are diffracted, obeying the refraction law. Namely diffraction and refraction accompany the refractive index modulating lens. Thus the refractive index modulating lens belongs to the category of diffraction lenses.
This is a kind of diffractive lenses which continuously vary refractive indices by a unit amplitude of λ/d. It is not easy to produce such a refractive index continually modulating type lens. Thus another diffractive lens is made by quantizing the refractive index into g steps which are defined by dividing the unit amplitude λ/d by g. A g-step quantized refractive index modulating function n g (r) is,
n g ( r )=(λ/ gd f ) int[g mod {( n− 1) d ( r )/λ,1 }]+n 0 . (56)
The division number g is an integer. It is convenient to determine g as an exponent of 2 (g=2 b ). For example, when g=16 (b=4),
n 16 ( r )=(λ/16 d f ) int[ 16 mod {( n− 1) d ( r )/λ,1 }]+n 0 . (57)
In the case of g=8 (b=3), the index modulating function is
n 8 ( r )=(λ/8 d f ) int[ 8 mod {( n− 1) d ( r )/λ,1 }]+n 0 . (58)
A 4 step index modulation function n 4 (r) is
n 4 ( r )=(λ/4 d f ) int[ 4 mod {( n− 1) d ( r )/λ,1 }]+n 0 . (59)
In the simplest case of g=2 (b=1), a binary index modulating function n 2 (r) is
n 2 ( r )=(λ/2 d f ) int[ 2 mod {( n− 1) d ( r )/λ,1 }]+n 0 . (60)
A transparency distribution lens modulating the transparency belongs to the category of diffractive type lenses. A 2-step transparency distributing lens is defined by a transparency modulating function T g (r)
T g ( r )= T 1 int[ 2 mod {( n− 1) d ( r )/λ,1 }]+T 0 . (61)
The present invention succeeds in prolonging the focal depth by utilizing laser beams composed of ultrashort pulses and a diffractive type lens and increasing the range of focal length fluctuation. The present invention can be realized by making use of all kinds of diffractive type lenses. The present invention is applicable to a Fresnel lens utilizing partially refraction beside diffraction and a thickness modulating lens having microslants and microprecpices produced by quantizing the slants of the Fresnel lenses. Furthermore, a refractive index modulating lens is also applicable to the present invention. In any case, the present invention deepens the focal depth by exploiting ultrashort pulses and a diffractive lens, inducing focal point fluctuation and adding the focal point fluctuation to the focal depth. Higher order diffractive Fresnel lenses are, in particular, more effective in increasing the focal depth longer than lower order ones. A hybrid lens composed of different kinds of diffractive lenses is applicable to the present invention. For example, a hybrid lens having a Fresnel lens and a refractive index modulating lens, which are stuck together, can lengthen the focal depth. It is allowable to combine two diffractive lenses of the same kind in the axial direction in the present invention. A radial hybrid lens having a first order Fresnel lens part within a boundary radius and a second order Fresnel lens part beyond the boundary radius, or vice versa, is applicable to the present invention. Such radially different diffraction order lenses are applicable to quantized step lenses and refractive index modulation lenses in realizing the present invention. All of the diffractive lenses are useful for practicing the present invention. This invention is a useful invention.
In a laser processing apparatus for boring holes in an object (a work piece), if the focal depth is shallow, accuracy in the distance between the lens and the object (a work piece) is rigorously required. The shallow focal depth prevents the laser processing apparatus from boring deep holes. When the bored hole is shallow, a diameter of the hole fluctuates in the direction of depth. The present invention substantially lengthens the focal depth by making use of ultrashort pulses and diffractive lenses and maintaining the Z-parameter (Zp=2fcΔt/Δi 2 ) to be less than 1 (Zp=2fcΔt/Δi 2 ≦1)
The present invention, which lengthens the focal depth, succeeds in lowering the accuracy required of the distance between the lens and the object (a work piece). The present invention enables a pulse laser to bore deep holes with a constant diameter in the depth direction.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an explanatory figure for showing a method of correcting color aberration induced in an ultrashort pulse laser beam proposed by Japanese Patent Laying Open No. 2003-305585. The color aberration is corrected by a special lens having a refractive front surface and a diffractive rear surface.
FIG. 2 is an explanatory figure of a laser beam and a lens for showing occurrence of a beamwaist, which has the maximum beam density and the smallest diameter at a focal point of the lens. The beam again widens after the beamwaist. The length enclosed by a dotted line is a definition of the focal depth ( FIG. 2 left figure). FIG. 2 right figure shows light power density by black tones. The length of the part having higher density is the focal length.
FIG. 3 is a graph of showing the relations between heights h(r) and radius coordinates (r) of a continual surface of a refractive lens (a), a saw-like zigzag surface of a Fresnel lens (b) which is made by cutting the continual surface of the refractive lens in turn into concentric circular rings having a definite height of λ/(n−1), and a binary surface of a binary lens which is produced by allocating the parts of over half height with 1-height and the other parts of under-half height with 0-height.
FIG. 4 is explanatory figures for showing focus multiplication of a diffraction lens for ultrashort pulses, which generates a definite wavelength width. FIG. 4 (right) is beam loci at a refractive lens which produces no extra increase of a focal depth in spite of the definite wavelength width. FIG. 4 (right) is beam loci at a diffractive lens which yields extra increase of a focal depth induced by the definite wavelength width of the ultrashort (femtosecond) pulses.
FIG. 5 is time-dependent changes of pulse laser wave packets converged by a refractive lens and a diffractive lens in the vicinity of the focus. The diffractive lens broadens the converging range and prolongs the focal depth.
FIG. 6 is a graph for showing the relation between the Z-parameter and the focal depth magnification rate. The abscissa is the Z-parameter (2fcΔt/Δi 2 ). The ordinate is the focal depth magnification rate.
FIG. 7 is a sectional view of a diffraction lens, rays and an object (a work piece) for showing that, when the apparatus having the ultrashort pulse laser and the diffractive lens bores a hole on an opaque object (a work piece), beam shielding at hole edges presents the laser beam from reaching the inner space and from producing a constant-diameter hole.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the boring processing of the present invention, preferable objects (work pieces) should be transparent to the laser light. Opaque materials are unsuitable for the boring processing. FIG. 7 shows a diffraction-type lens, a set of laser pulse rays with different wavelengths, and an object (a work piece) which is irradiated by the set of multiwavelength rays converged by a diffraction-type lens. If the object (a work piece) is transparent, outer rays can penetrate the object (a work piece). The set of the incident rays makes a cylindrical envelope. The set of the multiwavelength rays produces a constant-radius cylindrical hole through the object (a work piece). If the object (a work piece) is opaque, outer rays, which have shorter wavelengths and longer focal lengths, are shielded by the outer wall of the object (a work piece). Inner rays, which have longer wavelengths and shorter focal lengths, bore a hole on the front of the object (a work piece). After the front parts of the object (a work piece) are eliminated, outer rays can attain inner space of the bored hole. Namely the formation of the hole starts from the front and ends at the back of the object (a work piece). This invention enlarges the focal depth but does not enlarge laser power. The opaque wall rejects the outer rays at the beginning. Thus the hole bored in the opaque object (a work piece) by the present invention is not a constant-radius cylindrical hole but a decreasing-radius conical hole. It is desirable that the object (a work piece) is a transparent one for making the best use of the enlarged focal length of the present invention.
This invention enables ultrashort pulse lasers to enlarge effective focal depths in processing transparent objects (work pieces). Prolonged foal depths allow the ultrashort pulse laser to apply adiabatic, microscopic processings to resins, glass, sapphire, transparent semiconductors, and so on.
EMBODIMENT 1
Laser FWHM Pulse width: Δt=120 fs (1.2×10 −13 s)
Incident beam FWHM diameter: Δi=4.7 mm (w 0 =4.0 mm)
Lens Refractive Lens and Diffractive Lens
Focal Length: f 0 =100 mm
Z-parameter: 2f 0 cΔt/Δi 2 =0.32
The Z-parameter of 0.32 is between 0.25 and 1 (0.25<0.32<1), which satisfies the aforementioned requirement between 0.25≦Zp≦1.
The convergence properties of a refraction lens and a diffraction lens have been calculated on the abovecited conditions. FIG. 5 shows the results of calculations of power densities converged by the refraction lens and the diffraction lens. Left column figures of FIG. 5 demonstrate time-dependent spatial distributions of power density by the refractive lens. Right column figures of FIG. 5 show time-dependent spatial distributions of power density converged by the diffractive lens. The abscissa denotes distances. Individual figures have a length of 900 μm in the horizontal direction and a width in the vertical direction. Definition of t will be described later. Thus FIG. 5 demonstrates the time-dependent changes of power densities in the pre-focus 450 μm range and the post-focus 450 μm range of converging pulses by the refraction and diffraction lenses.
Since the light velocity is 3×10 8 m/s, it takes light 3 ps to pass the 900 μm length, which is a full span in FIG. 5 . The instance at which a pulse departs from the laser is not t=0. The moment at which the pulse attains the focus is designated to be t=1.0 ps. FIG. 5 denotes time-dependent variations in ±1.0 ps before and after t=1.0 ps (focus time).
First line sets show the power densities at t=0.0 ps. Second line sets denote the power density at t=0.5 ps. Third line sets show the power densities at t=1.0 ps, at which wave packets exist in the vicinity of the focus. Clear power densities appear, since the wave packet coincides with the focus. Fourth line sets show the power densities at t=1.5 ps. Fifth line sets denote the power densities at t=2.0 ps. Sixth line sets show time-averaged spatial distributions of the power densities.
In both cases of the refractive-type lens and the diffractive-type lens, the wavepackets move from the left to the right at the light velocity c. Wavepackets (left column) which have passed the refractive lens are obscure. The wavepackets are faint and dispersed in the directions vertical to the axis at t=0.0 ps, 0.5 ps, 1.5 ps and 2.0 ps. The wavepacket at t=1.0 ps is clear and converged in the vertical direction, since the wavepacket is just on the focus f 0 .
Except the focus wavepacket at f0, the 0.5 ps wavepacket is clearer than the 0.0 ps wavepacket. It is because the convergence effect of the lens at t=0.5 ps is stronger than that at t=0.1 ps. The 2.0 ps wavepacket is obscurer than the 1.5 ps wavepacket. It is because the once-converged wavepacket at t=2.0 ps expands again wider than that at t=1.5 ps.
The diffraction-type lens is entirely different from the refractive-type lens in the time-dependent change of wavepackets. At t=0.0 ps, the wavepacket stays at a point preceding the focus by 300 μm (first line). In spited of non-focal point, the t=0.0 ps wavepacket, which is partially converged, makes a cloud. At t=0.5 ps, the wavepacket passes at a point preceding the focus by 150 μm. The t=0.5 ps wavepacket forms a definite cloud (second line). At t=1.0 ps, the wavepacket passes at the focus. The t=1.0 ps wavepacket forms a definite cloud (third line). But the convergency is poorer than the refraction lens (third line of left column) at t=1.0 ps. The t=1.5 ps wavepacket passes a point following the focus by 150 μm, keeping enough density. At t=2.0 ps rays still form a wavepacket (fifth line of right column).
When parallel rays of a laser beam are converged by the diffraction lens, the diffracted rays form wavepackets of definite sizes between t=0.0 ps and t=2.0 ps in addition to the focal point at t=1.0 ps. The wavepacket maintains nearly a constant power density between t=0.0 ps and t=2.0 ps. This means poor convergency of the diffraction lens. Poor convergency is a weak point in the diffraction lens. The present invention converts the drawback into an advantage. The fact that diffracted rays form wavepackets with enough power density before and after the focus teaches us the prefocus rays and postfocus rays have enough power for laser processing.
The focal depth of the diffraction lens is prolonged to about 3.8 times as long as the focal depth of the refractive lens (1200 μm/320 μm). The diffractive lens has a function of prolong the focal depth.
The beam diameter (waist) at the focus (t=1.0 ps) of the diffractive lens is 1.54 times as big as that of the refractive lens. This means the inferiority of diffractive lenses in convergency to the refractive lens.
In the above example, the sizes of beamwaists, which are sections at foci, are different in the refractive lens ( FIG. 5 left column) and the diffractive lens ( FIG. 5 right column). The waist size difference should be taken into account for estimating the increase of the focal depth in the diffractive lens. Then the rate of the focal depths of the diffractive lens to the refractive lens is 3.8/1.54 2 =1.6 on the condition of equalizing the beamwaists. The focal depth of the diffractive lens is 1.6 times as large as that of the refractive lens under the condition of the same beamwaists. Dispersion of wavelengths produces many continual focal points aligning on the beam axis in the diffraction lens. The formation of many continual foci can be called “multifoci”.
FIG. 6 is a graph showing the relation between the Z-parameter and the focal depth multiplication rate on the condition of equalizing the beamwaist to the beamwaist of the refractive lens convergence. The Z-parameters and the focal depth multiplication rate are calculated for a variety of incident beam sizes, focal lengths, and pulse widths deviating up and down from the values of the above example. Results are plotted on the same graph of FIG. 6 . Blank rounds (∘) shows results of a calculation which varies the incident beam diameter FWHM Δi. Crosses (+) denotes results of another calculation which changes the focal length f. (×) shows results of another calculation which varies the pulse width FWHM Δt.
Focal depth and Z-parameter changes for variations of the three parameters Δi, f and Δt lie on a common curve in FIG. 6 . This fact means that the Z-parameter is a good parameter for describing the behavior of the focal depth changes. The focal depth multiplication rate increases as the Z-parameter falls. When Zp≦1, the focal depth multiplication rate is larger than 1.
When 0.25≦Zp≦1, the focal depth multiplication rate attains 1.7 in FIG. 6 . If the requirement 0.25≦Zp is abandoned, the range of Zp is extended to 0≦Zp≦0.25. The Zp within 0≦Zp≦0.25 gives a further bigger focal depth multiplication. Zp=0.03 raises the focal depth up to 4 times as long as the inherent focal length of the refractive lens convergence. The present invention is based upon an excellent idea which makes the best use of the focal length dispersion of diffractive lenses and wavelength dispersion of ultrashort pulses, which are inherent defects of diffractive lenses and ultrashort pulses, for lengthening the focal depth.
The present invention succeeds in lengthening the focal depth in the ultrashort pulse laser processing by adopting a diffraction lens having a Z-parameter less than 1 (Zp≦1), inducing wavelength dispersion, varying the focal length and making many continual foci aligning on the beam axis. The deep focal depth is desirable for boring a cylindrical (diameter-constant) deep hole. The deep focal depth is effective for processing thick objects (work pieces). When changes of surrounding conditions displace the focal point, the long focal depth prevents the laser power from fluctuating in the object (a work piece) and allows the pulse laser to realize homogeneous and stable processing. | Ultrashort pulse laser processing bores, welds or cuts objects (work pieces) by converging ultrashort laser pulses by a lens on the objects (work pieces) positioned at the focus and heating small spots or narrow lines on the objects (work pieces). Shortage of a focal depth of the lens prevents the ultrashort pulse laser processing from positioning the object (a work piece) and forming a deep, constant-diameter cylindrical hole. Z-parameter is defined to be Z=2fcΔt/Δi 2 , where Δt is a FWHM pulse width of the ultrashort pulse laser, Δi is a FWHM beam diameter of the ultrashort pulse, f is a focal length of the lens and c is the light velocity in vacuum. Selection of an optical system including a diffraction-type lens which gives the Z-parameter less than 1 (Z<1) prolongs the focal depth. Expansion of the focal depth facilitates the positioning of objects (work pieces) and enables the ultrashort pulse laser apparatus to bore a deep, constant-diameter cylindrical hole. | 96,712 |
BACKGROUND OF THE INVENTION 1. FIELD OF THE INVENTION
The present invention relates to measuring and testing equipment for semiconductor integrated circuits (ICs), and in particular to those devices which mount an IC and perform measuring and testing utilizing a measurement handler socket provided with probes which are brought into contact with outer leads arranged around the periphery of the IC mounting to achieve conduction.
2. Description of the Related Art
Semiconductor integrated circuits (semiconductor devices) are subjected to various function tests after manufacture, using a measurement handler. The structures of conventional IC measuring and testing devices are shown in FIGS. 1 and 2, of which FIG. 1 is a perspective view while FIG. 2 is a side view. As shown in these drawings, a mold-receiving base 2 is provided in the central portion of a measurement handler socket (hereinafter referred to simply as a socket) 1. This mold-receiving base 2 corresponds to the shape of the mold body 5 of the IC 4 to be measured, for example a rectangular shape, and guide members 7 for guiding the mold body 5 are formed in the four sides of the rectangle.
The IC 4 to be measured comprises the mold body 5 which has a top surface (upper surface) 5a and a bottom surface (lower surface) 5b, with a plurality of outer leads 6 provided protruding from the four edge surfaces around the periphery of the mold body 5. Each outer leads 6 protrudes horizontally form the edge of the mold body 5 to form a shoulder portion 6a at its root portion, is bent downward therefrom, and is then bent horizontally again at its end to form a leg portion 6b.
A plurality of probes 3 are provided at the peripheries of the four sides of the mold-receiving base 2 and corresponding to the outer leads 6 of the IC 4. The mold-receiving base 2 is mounted on a substrate 9 via a spring 12.
The IC 4 to be measured is suction-supported by a suction arm 11 for handling, such as a vacuum chuck or the like, on the top surface 5a thereof, is lowered onto the mold-receiving base 2 in the direction of the arrow A, the bottom surface 5b of the mold body 5 is guided in the direction of arrow B along the guide member 7, and thereby the IC 4 is set into the socket 1.
FIGS. 3A to 3E are explanatory diagrams of the procedures of an IC measuring and testing method of the related art. First, as shown in FIG. 3A, the suction-supported IC 4 whose top surface 5a is raised by the suction arm 11 is aligned in a position sufficiently close to the mold-receiving base 2 above the socket 1 by an image processing or other suitable positioning means. There the vacuum of the suction arm 11 is released and the IC 4 is dropped into place. By this means, as shown in FIG. 3B, the mold body 5 of the IC 4 is seated and supported within the guide member 7 surrounding the mold-receiving base 2. In this state the end horizontal portions (leg portions) 6b of the outer leads 6 of the IC 4 are in a non-contact state separated from above the probes 3.
Next, as shown in FIG. 3C, contactors 10 are lowered to push down the leg portions 6b of the outer leads 6 of the IC 4 against the resistance of the spring 12, thus causing the outer leads 6 to contact and obtain conduction with the corresponding probes 3. In this state, predetermined measuring and testing can be performed on the IC 4 by a measuring and testing circuit (not shown) connected thereto via the terminals 3a of the probes 3.
Upon completion of the predetermined measuring and testing and acquisition of desired measurement data, the contactors 10 are raised and separated from the outer leads 6 as shown in FIG. 3D, by which means the outer leads 6 are separated from the probes 3. Subsequently, the suction arm 11 is lowered to suction-support the top surface 5a of the mold body 5 of the IC 4 and then raised, extracting the IC 4 from the mold-receiving base 2 as shown in FIG. 3E and transferred it to the next process.
However, in the IC measuring and testing method by means of a conventional measurement handler as described above, the outer leads 6 of the IC 4 can strike against the guide members 7 of the socket 1 when the IC 4 is set in the socket 1 due to slight alignment errors or inconsistencies in the outer dimensions of the IC, leading to the possibility of deformation of the leads. This is likely to occur particularly in cases where the IC itself is large and has many pins or where the leads are miniaturized.
SUMMARY OF THE INVENTION
The object of the present invention is to provide an IC measuring and testing device which can overcome the disadvantage of leads deforming due to the guide members etc. of the socket striking against the outer leads of the IC when the IC is set.
The present invention was designed in order to achieve this object, and is an IC measuring and testing device which comprises a measurement handler socket, provided with a mold-receiving base having around its periphery guide members corresponding to the shape of an IC mold body to be measured and probes for contacting the outer leads of the IC, and a handling means for suction-supporting the IC and mounting it in the mold-receiving base, and which performs measuring and testing of an IC mounted on the mold-receiving base by means of the handling means, wherein the guide members separate the corresponding outer leads of the IC and the end portions of the probes are arranged so as to be inserted into these separated portions.
A pressure member is also provided in the present invention for applying pressure from above on the IC mounted in the mold-receiving base by the handling means, via the mold body.
The present invention is further provided with guide members at the four sides of the rectangular shaped mold-receiving base.
The present invention also includes a method for performing measuring and testing of the IC in the IC measuring and testing device, in which, firstly, the IC to be measured is suction-supported by the handling means, then the IC suction-supported by the handling means is mounted facing the mold-receiving base in a state where its top surface is facing downward, whereafter the root portions of the outer leads extending from the mold body are brought into contact with the probe terminal portions within the separated portions by the bottom surface of the mold body of the IC being depressed from above by the handling means, so that conduction is obtained between the outer leads and the probes.
In addition, the present invention is a method for performing measuring and testing of an IC using an IC measuring and testing device wherein, firstly, the IC to be measured is suction-supported by the handling means, then the IC suction-supported by the handling means is mounted facing the mold-receiving base in a state where its top surface is facing downward, whereafter the root portions of the outer leads extending from the mold body are brought into contact with the probe terminal portions within the separated portions by the bottom surface of the mold body of the IC being subjected to pressure from above by the pressure member, so that the electrical conduction is achieved between outer leads and the probes.
In the present invention, since the guide members provided around the periphery of the mold-receiving base are separated from the corresponding outer leads of the IC and the terminal portions of the probes are arranged inserted into the separation portion, the mold body is guided by the guide members when the IC to be measured is mounted in the mold-receiving base with the top surface of the IC facing downward, by which means the guide members etc. of the socket do not contact and are not deformed by the outer leads.
Also in the present invention, with regard to the IC mounted in the mold-receiving base, by applying pressure on the bottom surface of the mold body of the IC from above by way of the handling means, the root portions of the outer leads are brought into contact with the probes arranged in the separation portions of the guide members and conduction can be achieved between the outer leads and probes.
Further, in the present invention, with regard to the IC mounted in the mold-receiving base as described above, by applying pressure on the bottom surface of the mold body of the IC from above by means of the pressure member, the root portions of the outer leads are brought into contact with the probes arranged in the separation portions of the guide members and conduction can be attained between the outer leads and the probes.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects and advantages of the present invention will become better understood with reference to the following description, appended claims and accompanying drawings wherein
FIG. 1 is a perspective view showing a conventional IC measuring and testing device;
FIG. 2 is a cross-sectional side view of the conventional IC measuring and testing device;
FIG. 3A is a cross-sectional side view of a conventional IC measuring and testing method, showing a suction-supported IC whose top surface is raised by a suction arm and aligned at a position sufficiently close to a mold-receiving base above a socket;
FIG. 3B is a cross-sectional side view of a conventional IC measuring and testing method, showing the IC being dropped into place by the release of the vacuum of the suction arm so that the mold body of the IC is seated and supported within a guide member surrounding the mold-receiving base;
FIG. 3C is a cross-sectional side view of a conventional IC measuring and testing method, showing contactors being lowered to push down leg portions of outer leads of the IC against the resistance of a spring, thus causing the outer leads to contact and achieve conduction with corresponding probes;
FIG. 3D is a cross-sectional side view of a conventional IC measuring and testing method, showing the contactors being raised and separated from the outer leads, separating the outer leads from the probes.
FIG. 3E is a cross-sectional side view of a conventional IC measuring and testing method, showing the suction arm being lowered to suction-support the top surface of the mold body of the IC and then raised, extracting the IC from the mold-receiving base and transferring it to the next process;
FIG. 4 is a perspective view showing a first embodiment of an IC measuring and testing device according to the present invention;
FIG. 5 is an enlarged perspective view showing the main components of the mold-receiving base 2 shown in FIG. 4;
FIG. 6 is a cross-sectional side view of the device shown in FIG. 4;
FIG. 7A is a cross-sectional side view of a second embodiment of the present invention, which is an IC measuring and testing method, showing the bottom surface of an IC being suction-supported by the suction arm to align the IC at a position sufficiently close to the mold-receiving base above the socket;
FIG. 7B is a cross-sectional side view of the IC measuring and testing method of the second embodiment of the present invention, showing the IC being dropped into place by the release of the vacuum of the suction arm the top surface of the mold body being guided into the guide members at the periphery of the mold-receiving base with the leg portions of the outer leads facing upwards;
FIG. 7C is a cross-sectional side view of the IC measuring and testing method of the second embodiment of the present invention, showing the suction arm being lowered to depress the bottom surface of the IC downwards against the resistance of the spring, thus causing the shoulder portions of the outer leads to contact the end portions of the probes and achieve electrical conduction;
FIG. 7D is a cross-sectional side view of the IC measuring and testing method of the second embodiment of the present invention, showing the suction arm being raised and the IC being extracted from the socket upon completion of predetermined measuring and testing and acquisition of desired measurement data, to be transferred to the next process;
FIG. 8 is a cross-sectional side view showing an example of the device of the first embodiment of the present invention applied to a DIP type IC;
FIG. 9 is a cross-sectional side view showing a third embodiment of an IC measuring and testing device according to the present invention;
FIG. 10 is a perspective view showing the shape of a pressure member of the third embodiment;
FIG. 11A is a cross-sectional view of an IC measuring and testing method according to a fourth embodiment of the present invention, showing the pressure member disposed at the periphery of the socket being advanced in two or four directions, positioning and arranging the pressure member above the IC;
FIG. 11B is a cross-sectional view of the IC measuring and testing method according to the fourth embodiment of the present invention, showing the pressure member being lowered and the bottom surface of the mold body of the IC being depressed by pressure portions to push the IC downwards against the resistance of the spring, thus causing the shoulder portions of the outer leads to contact the end portions of the probes and achieve electrical conduction;
FIG. 12 is a view showing an example of the device of the third embodiment of the present invention applied to a DIP type IC;
FIG. 13A is a perspective view showing the shape of a pressure member in a fifth embodiment of the present invention which is used in the IC measuring and testing device of the second embodiment;
FIG. 13B is a plan view of pressure members as shown in FIG. 13A being applied to an IC, advancing from opposite directions and enabling uniform pressure to be applied to the bottom surface of the mold body.
FIG. 14A is a plan view of pressure portions of a pressure member of a sixth embodiment of the present invention and the operation thereof;
FIG. 14B is a side view of the pressure portions of the pressure member shown in FIG. 14A and the operation thereof;
FIG. 15A is another plan view of pressure portions of the pressure member of the sixth embodiment and the pressure operation thereof;
FIG. 15B is another side view of the pressure portions of the pressure member shown in FIG. 15A and the pressure operation thereof; and
FIG. 16 is a drawing showing an example of a pressure member of a seventh embodiment of the present invention and the operation thereof, when applied to another type of IC.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereafter, embodiments of the present invention will be described in detail with reference to the drawings.
FIG. 4 is a perspective drawing showing a first embodiment of an IC measuring and testing device according to the present invention, FIG. 5 is an enlargement of the main components thereof, and FIG. 6 is a side view thereof. As shown in the drawings, a mold-receiving base 32 is provided in the central portion of the socket 31. This mold-receiving base is of a shape corresponding to the shape of a mold body 35 of an IC to be measured, for example a rectangular shape, and guide members 37 (FIG. 5 and FIG. 6) for guiding the mold body 35 are formed on the outer edges of the four sides of this rectangular shape. These guide members 37 comprise a plurality of guide edges 37a separately arranged corresponding to the positions of a plurality of outer leads 36 of the IC 34.
The IC 34 to be measured comprises the mold body 35 having a top surface (upper surface) 35a and a bottom surface (lower surface) 35b, the mold body 35 being provided a plurality of outer leads 36 extending from the four side surfaces surrounding the mold body 35. The outer leads 36 extend from the side surfaces of the mold body 35, form shoulder portions 36a at the lead root portion thereof, bend downward therefrom, and further bend horizontally at their end portions to form leg portions 36b.
The mold-receiving base 32 is mounted on a substrate 39 via a spring 42. Outside the four sides of the mold-receiving base 32 are provided a plurality of probes corresponding to the outer leads 36 of the IC 34. The end portions of the probes 33 are inserted in the gaps of the separation portions of the guide members 37, i.e. between each of the abutting guide edges 37a.
The IC 34 to be measured, in a state wherein it is inverted so that the top surface 35a is facing downward (the bottom surface 35b faces upward), is suction-supported at its bottom surface 35b by a suction arm 41 for handling, such as a vacuum chuck or the like. The IC 34 inverted and supported in this manner is lowered onto the mold-receiving base 32 as shown by arrow A (FIG. 4) and the upper surface 35a of the mold body is guided along the guide members 37 as shown by arrow C (FIG. 6), by which means the IC 34 is set in the socket 31.
FIGS. 7A to 7D are explanatory drawings showing the procedures of an IC measuring and testing method according to a second embodiment of the present invention and utilized in the device of the first embodiment. First, as shown in FIG. 7A, the bottom surface 35b of the IC 34, which has been inverted and is at the top thereof, is suction-supported by the suction arm 41, and the IC 34 is aligned to a position sufficiently close to the mold-receiving base 32 above the socket 31 by an imaging process or another suitable positioning means.
At this point, as shown in FIG. 7B, the vacuum of the suction arm 41 is released to drop the IC 34, thereby guiding the top surface 35a of the mold body 35 of the IC 34 into the guide members 37 at the periphery of the mold-receiving base 32 so that the IC 34 is set on the mold-receiving base 32 in a state where the end of the leg portions 36b of the outer leads 36 are facing upwards. In this state, the shoulder portions 36b of the outer leads 36 are separated from the probes 33, i.e. in a state wherein they are disconnected. Also, the outer leads 36 are positioned above gaps formed between the guide edges 37a (refer to FIG. 5) of the guide members 37. Further, the probes 33 are inserted in the gaps between the guide edges 37a corresponding to the outer leads 36.
Next, as shown in FIG. 7C, the suction arm 41 is lowered to depress the bottom surface 35b of the IC 34 and push it downwards against the resistance of the spring 42. By this means, the shoulder portions 36a of the outer leads 36 contact the end portions of the probes 33 and achieve electrical conduction. In this state, various types of signal transmissions with a measuring and testing circuit (not shown) via the terminals 33a of the probes 33 are performed, so that predetermined measuring and testing is performed on the IC 34.
Upon completion of the predetermined measuring and testing and acquisition of desired measurement data, the suction arm 41 is raised and the IC 34 is extracted from the socket 31 as shown in FIG. 7D, and is transferred to the next process.
In the IC measuring and testing device of the second embodiment, since a conductive state between the outer leads 36 and the probes 33 is obtained by the suction arm 41 applying pressure from above on the bottom surface 35b of mold body 35 of the IC 34, this IC measuring and testing device corresponds to any package shape in which the IC 34 thereof has shoulder portions 36a at the root portions of the outer leads 36, i.e. not only surface-mounted type packages such as QFPs (quad flat packages), SOPs (small outline packages) and the like, but also pin-insertion type packages such as DIPs (dual inline packages), S-DIPs (shrink dual inline packages) and the like, and further, surface-mounted type packages such as QFJs (quad flat J-leaded packages), SOJs (small outline J-leaded packages) and the like.
FIG. 8 shows an example wherein the present invention is applied specifically to a DIP-type IC 34 from among the various package shapes described above, this case being the same as the above-described embodiment, wherein conduction is attained between the outer leads 36 and the probes 33 by the suction arm 41 applying pressure from above on the bottom surface 35b of the mold body 35 of the IC 34.
Also, in the conventional IC measuring and testing device previously described, as shown in FIG. 3, since the outer leads 6 of the IC 4 mounted on the mold-receiving base 2 are of a structure such that they are depressed by the connectors 10, during repetition of measuring and testing, solder with which the outer leads 6 are plated transfers to the connectors 10, so that maintenance for removing this solder which has become attached to the connectors 10 must necessarily be performed at regular intervals so that short circuiting and the like does not occur between the leads when continuing measuring and testing in such a state. However, because the first embodiment has a structure wherein the mold body 35 of the IC 34 mounted on the mold-receiving base 32 is depressed by the suction arm 41, and the outer leads do not make contact, the above-described maintenance is unnecessary.
FIG. 9 is a side view showing a third embodiment of the IC measuring and testing device according to the present invention. In this drawing, 61 is a socket, 62 is a mold-receiving base, 63 are probes, 67 are guide members, 69 is a substrate, 71 is a suction arm, and 72 is a spring, the structures of which are the same as in the case of the first embodiment.
In this third embodiment, in addition to the above-described structures, a pressure member 13, for applying pressure from above on the IC 64 mounted on the mold-receiving base 62 by the suction arm 71 via the mold body 65 thereof, are provided.
FIG. 10 is a perspective view showing the shape of a pressure member of the third embodiment. As shown in the drawing, a pressure portion 73a, made from an insulating material for example, is provided on a surface of the end portion of the pressure member 73 facing the mold body 65. This pressure portion 73a is formed corresponding to the shapes of the outer leads 66 and the mold body 65 of the IC 64 to be measured. Also, an attachment hole 37b is perforated in the end portion of the pressure member 73, the pressure member 73 being fixed by a driving means (not shown) via this attachment hole 73b. At this point, the driving means described above moves the pressure member 73 in the up and down or left and right directions according to a predetermined procedure.
Next, an IC measuring and testing method according to a fourth embodiment will be described. Firstly, in the same manner as is shown in FIG. 7A described above, the bottom surface 65b of the IC 64, which has been inverted and faces upwards, is suction-supported by the suction arm 71, and the IC 64 is aligned to a position sufficiently close to the mold-receiving base 62 above the socket 61 by an imaging process or another suitable positioning means.
At this point, in the same manner as is shown in FIG. 7B, the vacuum of the suction arm 61 is released to drop the IC 64, thereby guiding the top surface 65a of the mold body 65 of the IC 64 into the guide members 67 at the periphery of the mold-receiving base 62 so that the IC 64 is set on the mold-receiving base 62 in a state where the end of the leg portions 66b of the outer leads 66 are facing upwards.
In this state, the shoulder portions 66b of the outer leads 66 are separated from the probes 63, i.e. in a state wherein they are disconnected. Also, the outer leads 66 are positioned above gaps formed between the guide edges 67a of the guide members 67. Further, the probes 63 are inserted in the gaps between the guide edges 67a corresponding to the outer leads 66.
Then, when the IC 64 has been mounted on the mold-receiving base 62, the suction arm 71 is retracted away from the socket 61.
Next, as shown in FIG. 11A, the pressure member 73 disposed at the periphery of the socket 61 is advanced in two or four directions as shown by the arrows on the drawing, positioning and arranging the pressure member 73 above the IC 64.
Subsequently, as shown in FIG. 11B, the pressure member 73 is lowered and the bottom surface 65b of the mold body 65 of the IC 64 is depressed by the pressure portions 73a provided at the end portions thereof to push the IC 64 downwards against the resistance of the spring 72. Thereby, the shoulder portions 66a of the outer leads 66 contact the end portions of the probes 63, and achieve electrical conduction. In this state, various types of signal transmissions with a measuring and testing circuit (not shown) via the terminals 63a of the probes 63 are performed, so that predetermined measuring and testing is performed on the IC 64.
Upon completion of the predetermined measuring and testing and acquisition of desired measurement data, the pressure member 73 is raised from the state shown in FIG. 11B so that it is retracted to the periphery of the socket 71 and the IC 64 is again suction-supported by the suction arm (not shown) for IC extraction and transferred to the next process.
In this way, because the third and fourth embodiments are provided with the pressure member 73 for applying via the mold body 65, pressure from above on the IC 64 mounted in the mold-receiving base 62 after the IC 64 suction-supported by the suction arm 71 is mounted in the mold-receiving base 62, by using the pressure member 73 to depress the mold body 65 and thereby achieve conduction between the outer leads 66 and the probes 63, the next IC 64 to be measured can be suction-supported by the suction arm 71 while the pressure member is depressing the mold body 65 of the currently measured IC 64 downward, then the IC 64 after measuring can be extracted from the socket 61 by a suction arm (not shown) for IC extraction, enabling the next IC 64 to be measured to be mounted in the mold-receiving base 62.
Also in the third and fourth embodiments, by forming the shapes of the pressure portions 73a of the pressure member 73 to correspond to the package shape of the IC 64, in not only surface-mounted type QFP and SOP ICs, but any type of ICs, if they are ICs 64 having shoulder portions 66a at the root portions of the outer leads 66 (S-DIPs, QFJs, SOJs, etc.), such as the DIP-type IC 64 shown FIG. 12 for example, the root portions (shoulder portions 66a) of the outer leads protruding from the mold body 65 can be brought into contact with the end portions of the probes 63 within the separation portions of the guide members 67 to achieve conduction between the outer leads 66 and the probes 63, by applying pressure on the mold body 65 of the IC 64 from above with the pressure portions 73a of the pressure member 73 as shown in the drawings.
Further, since the third and fourth embodiments have structures wherein the mold body 65 of the IC 64 mounted in the mold-receiving base 62 is depressed by the pressure member 73 and there is no contact with the outer leads 66 as in the previously described prior art, it is not necessary to perform maintenance to periodically remove solder attached to contactors 70.
Note that in the structures of the third and fourth embodiments, the shape of the pressure member 73 need not be restricted to that shown previously in FIG. 10, but may be variously shaped according to the shapes of the mold body 65 of the IC 64 and outer leads thereof.
Next, a fifth embodiment of the present invention will be described. Even if the IC is of the same QFP type as described above, a pressure portion 83a of triangular shape disposed at the end of the pressure member 83, as shown in FIG. 13A for example, can be provided as the pressure member for applying pressure on the IC from above, the pressure portions of this pressure member advancing from opposite directions of the IC mounted in the mold-receiving body as shown in FIG. 13B, enabling uniform pressure to be applied to the bottom surface 85b of the mold body 85.
FIG. 14 is an explanatory drawing of a sixth embodiment of the present invention which is an example of a variation in shape of the third embodiment, FIG. 14A being a plan block drawing thereof, and FIG. 14B being a side block drawing thereof. In the drawings, the ends of the pressure member 113 are formed in a thin tapering shape, providing pressure portions 113a of protruding shape in predetermined gaps in the lower surface of the thin portion thereof. These pressure portions 113a are portions for applying pressure from directly above the mold body 105 of the IC 104 mounted in a mold-receiving base (not shown), the gaps thereof being set corresponding to the outer dimensions of the IC 104 to be measured.
In other words, in the case of applying pressure on an IC 104 whose outer dimensions are small, as shown by the solid lines in the drawing, by advancing the pressure member 113 shown in FIG. 14B to a position above the IC 104 then lowering it, the pressure portions 113a provided extending from the ends as shown in FIGS. 15A and 15B can applying pressure from above on a small IC 104.
On the other hand, in the case of applying pressure to an IC 104 whose outer dimensions are large as shown by the double broken lines in the drawing, in the same manner as that described above, by advancing the pressure member 113 shown in FIG. 14B to a position above the IC 104 and lowering it, the IC 104 can be depressed from above by both the pressure portions 113a provided extending from the ends as shown in FIGS. 15A and 15B and further pressure portions provided extending therefrom.
In the modes of these embodiments, since one pressure member 113 can be commonly used even in cases where the outer dimensions of the IC 104 to be measured vary, it is unnecessary to perform conversion operations on the pressure member 113 with changes in the dimensions of the IC 104 to be treated.
Next, a seventh embodiment of the present invention will be described. Note that in the above-described embodiments explanation was given with respect to cases where a QFP-type IC 104 was depressed. However, in cases other than this, by forming the end shapes of the pressure member 113 stepwise in thin shapes as shown in FIG. 16 for example and providing pressure portions 113a at the thin portions thereof, the pressure member 113 can be made to correspond to an SOP-type IC 124.
According to the present invention as described above, since the guide members provided at the periphery of the mold-receiving base are separated corresponding to the leads of the IC and the ends of the probes are inserted and disposed in these separation portions, when the IC to be measured is mounted in the mold-receiving base in a state where the top surface thereof is facing downwards, because the mold body is guided by the guiding portions and the outer leads do not contact and deform the guide members of the socket or the like, solder junction deficiencies, short circuits between the leads and the like which give rise to lead deformation when the IC is mounted are prevented and mechanical reliability is improved, and improvement in production yields can be expected.
Also, according to the present invention, with respect to the IC mounted in the mold-receiving base, by applying pressure on the bottom surface of the mold body from above with a handling means, the root portions of the outer leads are brought into contact with the probes disposed in the separation portions of the guide members and conductivity can be achieved between the outer leads and the probes, thus rendering unnecessary provision of contactors separate to the handling means as in the prior art, thereby simplifying the structure of the device.
Further according to the present invention, with respect to the IC mounted in the mold-receiving base by the handling means, by applying pressure on the bottom surface of the mold body from above by means of the pressure member, the root portions of the outer leads are brought into contact with the probes disposed in the separation portions of the guide members and conductivity can be achieved between the outer leads and the probes. Consequently, since the next IC to be measured can be suction-supported by the handling means while the pressure member is applying pressure to the mold body, then the IC after measuring can be extracted from the socket, making it possible to mount the next IC to be measured in the mold-receiving base immediately thereafter, high performance measuring and testing can be expected.
In addition, according to the present invention, with respect to the IC mounted in the mold-receiving base by the handling means, since the present invention is devised so that a conductive state can be achieved between the outer leads and the probes by applying pressure to the bottom surface of the mold body from above by means of the handling means or pressure member, it can be made to correspond to any package shape in which the IC has shoulder portions at the root portions of the outer leads. | An IC measuring and testing device and measuring and testing method comprising a measurement handler socket provided with mold-receiving base having guiding members corresponding to the shape of a mold body of an IC to be tested around its periphery and probes for contacting outer leads of the IC, and a suction arm for suction-supporting the IC and transferring it to the mold-receiving base, the IC measuring and testing device performing measuring and testing on the IC mounted in the mold-receiving base by means of the suction arm, the guide members corresponding to and separated from the outer leads of the IC, and terminal portions of the probes being arranged inserted into these separation portions. As a result, when the IC is set, the guide members and the like of the socket can be prevented from striking against the outer leads of the IC and deforming them. | 33,362 |
TECHNICAL FIELD OF INVENTION
[0001] The present invention relates to an intraocular lens (IOL) having variable optical power and containing two immiscible liquids.
BACKGROUND
[0002] During cataract surgery, the patient lens is removed and replaced by a fix plastic lens, which deprives the patient of accommodation capabilities. Intraocular lens (IOL) implants are mostly developed to replace a lens from patients that suffer from cataract. This surgery operation prevents the patient from going blind and many inventions have been developed to provide to the patient the capability of focusing on objects at various distances from the eye.
[0003] Usually, the focusing capability for a healthy person is about 15 m −1 , meaning a focus from infinity to about 6 cm. This range may reduce as the patient ages down to few m −1 , or diopters.
[0004] IOL implants have been developed primarily to replace the patient lens at one fixed focus. Such an implant is folded and inserted in the lens cavity through a tubular means in order to reduce as much as possible the size of the corneal incision. However, such inventions may be limited because patient is only recovering vision at a given focus. Therefore the patient is unable to focus on objects at various distances.
[0005] Variable focusing IOL implants have been developed. Many of variable focusing IOL implants are based on the capability of the patient to use the eye's ciliary muscles to vary the focus and, thus, actuate the IOL implant instead of the eye's original lens. Such variable focusing IOL implants may vary the focus by a mechanical displacement of a fixed focus lens, or a lens deformation.
[0006] Variable focusing may also be performed using microfluidic means. In such IOL implants, a fluid may be injected from a reservoir into the optical path to deform the interface and, thus, change the optical power of the IOL implant. In such devices, the fluid reservoir may also be connected to the ciliary muscles. Therefore, implying that the ciliary muscles will still have the strength to actuate the device. This is not always the case for patients after a certain age, and especially for patients suffering from presbyopia.
[0007] Recently, Varioptic has described an IOL implant based on electrowetting actuation and made of two immiscible liquids on an insulating and hydrophobic surface (see WO2007107589). The IOL implant is encapsulated in a foldable structure, such that the device may be folded during the implantation process. However, the fluids used in the IOL device, and how to fold the device without disturbing the liquids confinement has been previously undisclosed.
[0008] One object of the present disclosure is to provide an IOL implant capable of being folded and unfolded during the implantation process thus minimizing the ocular incision without disturbing the performance of the IOL device.
SUMMARY
[0009] In a first aspect, the invention provides an intraocular variable focus implant comprising a non-conducting liquid with a melting temperature above 0° C., a conducting liquid, a liquid interface formed by the non-conducting and conducting liquids, a first electrode in contact with the conducting liquid, a second electrode insulated from the conducting liquid, wherein the liquid interface is movable by electrowetting according to a change in a voltage applied between the first and second electrodes.
[0010] In some embodiments of the first aspect, the invention provides an intraocular variable focus implant wherein the non-conducting liquid comprises a mixture of compounds wherein at least one of the compounds has a melting temperature above intraocular temperature.
[0011] In some embodiments of the first aspect, the invention provides an intraocular variable focus implant wherein the non-conducing liquid has a melting temperature above 20° C.
[0012] In some embodiments of the first aspect, the invention provides an intraocular variable focus implant wherein the non-conducing liquid has a melting temperature above 10° C.
[0013] In some embodiments of the first aspect, the invention provides an intraocular variable focus implant comprising a first flexible transparent film comprising a hydrophilic surface in contact with the conducting liquid, and a second flexible transparent film comprising a hydrophobic surface in contact with the non-conducting liquid.
[0014] In some embodiments of the first aspect, the invention provides an intraocular variable focus implant comprising one or more structural films sealed to the first and second flexible transparent films, and one or more circuit components disposed the one or more structural films, wherein the first and second electrodes are disposed on the one or more structural films, and wherein the circuit components control the voltage applied.
[0015] In some embodiments of the first aspect, the invention provides an intraocular variable focus implant wherein the non-conducing liquid has a melting temperature above 20° C.
[0016] In some embodiments of the first aspect, the invention provides an intraocular variable focus implant wherein the non-conducting liquid comprises a mixture of compounds and wherein at least one of the compounds has a melting temperature above intraocular temperature.
[0017] In some embodiments of the first aspect, the invention provides an intraocular variable focus implant wherein one of the compounds in the non-conducting liquid acts as a membrane between the non-conducting and conducting liquids below the intraocular temperature and above 0° C.
[0018] In some embodiments of the first aspect, the invention provides an intraocular variable focus implant wherein the non-conducting liquid comprises one or more compounds selected from the list consisting of a linear alkane [C n H 2n+2 ] where n is greater than 15 and less than 22, a diphenyl alkane [C n H 2n —(C 6 H 5 ) 2 ] where n is greater than 1 and less than 5, vinyl triphenylsilane, diphenylsulfide, palmitic acid, 1,4,-di-ter-butylbenzene, 1-methylfluoene, 9,10-dihydroanthracene, fluorene, methyltriphenylsilane, allyltriphenylsilane, ethyltriphenylsilane, and a cycloalkane C n H 2n where n is greater than 6 and less than 15.
[0019] In some embodiments of the first aspect, the invention provides an intraocular variable focus implant wherein the non-conducting liquid comprises less than 20% by weight of phenyltrimethyl germane, diphenyldimethylgermane, or a mixture thereof.
[0020] In some embodiments of the first aspect, the invention provides an intraocular variable focus implant wherein more than 80% by weight of the compounds have a melting temperature between 10° C. and 37° C.
[0021] In some embodiments of the first aspect, the invention provides an intraocular variable focus implant wherein the non-conducting liquid contains less than 20% by weight of organosilanes.
[0022] In some embodiments of the first aspect, the invention provides an intraocular variable focus implant wherein the intraocular variable focus implant is maintained at a temperature below the melting temperature of the compound while the compound, in liquid form, is disposed into the intraocular variable focus implant.
[0023] In a second aspect, the invention provides a method of manufacturing a variable focus implant, the method comprising: disposing in the implant a non-conducting liquid with a melting temperature above 0° C., and disposing in the implant a conducting liquid, wherein a liquid interface is formed by the non-conducting and conducting liquids and the liquid interface is movable by electrowetting according to a change in a voltage applied between a first and second electrode.
[0024] In some embodiments of the second aspect, the invention provides a method comprising: disposing the non-conducting liquid at a temperature above the melting temperature of the non-conducting liquid, and cooling the non-conducting liquid to below the melting temperature of the non-conducting liquid.
[0025] In some embodiments of the second aspect, the invention provides a method wherein the non-conducting liquid comprises a mixture of compounds wherein at least one of the compounds has a melting temperature above intraocular temperature.
[0026] In some embodiments of the second aspect, the invention provides a method comprising: disposing one compound of the mixture of compounds at a temperature above the melting temperature of the one compound, and cooling the one compound to below the melting temperature of the one compound.
[0027] In some embodiments of the second aspect, the invention provides a method comprising: disposing a first compound of the mixture of compounds at a temperature above the melting temperature of the first compound, cooling the first compound to below the melting temperature of the first compound, disposing a second compound of the mixture of compounds at a temperature below the melting temperature of the first compound and above the melting temperature of the second compound, and cooling the second compound to below the melting temperature of the second compound.
[0028] In some embodiments of the second aspect, the invention provides a method wherein the second compound is disposed in liquid form while the intraocular variable focus implant is maintained at a temperature below the melting temperature of the compound.
[0029] In some embodiments of the second aspect, the invention provides a method wherein the non-conducing liquid has a melting temperature above 20° C.
[0030] In some embodiments of the second aspect, the invention provides a method wherein the non-conducing liquid has a melting temperature above 10° C.
[0031] In some embodiments of the second aspect, the invention provides a method wherein one of the compounds in the non-conducting liquid acts as a membrane between the non-conducting and conducting liquids below the intraocular temperature and above 0° C.
[0032] In some embodiments of the second aspect, the invention provides a method wherein the non-conducting liquid comprises one or more compounds selected from the list consisting of a linear alkane [C n H 2n+2 ] where n is greater than 15 and less than 22, a diphenyl alkane [C n H 2n —(C 6 H 5 ) 2 ] where n is greater than 1 and less than 5, vinyl triphenylsilane, diphenylsulfide, palmitic acid, 1,4,-di-ter-butylbenzene, 1-methylfluoene, 9,10-dihydroanthracene, fluorene, methyltriphenylsilane, allyltriphenylsilane, ethyltriphenylsilane, and a cycloalkane C n H 2n , where n is greater than 6 and less than 15.
[0033] In some embodiments of the second aspect, the invention provides a method wherein the non-conducting liquid comprises less than 20% by weight of phenyltrimethyl germane, diphenyldimethylgermane, or a mixture thereof.
[0034] In some embodiments of the second aspect, the invention provides a method wherein more than 80% by weight of the compounds have a melting temperature between 10° C. and 37° C.
[0035] In some embodiments of the second aspect, the invention provides a method wherein the non-conducting liquid contains less than 20% by weight of organosilanes.
[0036] In a third aspect, the invention provides an intraocular variable focus implant comprising: a conducting liquid with a melting temperature below intraocular temperature and above 0° C., a non-conducting liquid, a liquid interface formed by the non-conducting and conducting liquids, a first electrode in contact with the conducting liquid, a second electrode insulated from the conducting liquid, wherein the liquid interface is movable by electrowetting according to a change in a voltage applied between the first and second electrodes.
[0037] In some embodiments of the third aspect, the invention provides an intraocular variable focus implant wherein the conducing liquid has a melting temperature above 20° C. and bellow 37° C.
[0038] In some embodiments of the third aspect, the invention provides an intraocular variable focus implant wherein the conducing liquid has a melting temperature above 10° C. and bellow 37° C.
[0039] In some embodiments of the third aspect, the invention provides an intraocular variable focus implant wherein the conducting liquid comprises less than 10% by weight of a gelling agent.
[0040] In some embodiments of the third aspect, the invention provides an intraocular variable focus implant wherein the gelling agent is selected from the list consisting of alginic acid, sodium alginate, potassium alginate, ammonium alginate, calcium alginate, gelatin, furcellaran or polysaccharides like agarose, carrageenan, pectin, or a mixture thereof.
[0041] In some embodiments of the third aspect, the invention provides an intraocular variable focus implant wherein the conducting liquid comprises a mixture of compounds wherein at least one of the compounds has a melting temperature above intraocular temperature.
[0042] In some embodiments of the third aspect, the invention provides an intraocular variable focus implant wherein one of the compounds in the conducting liquid acts as a membrane between the non-conducting and conducting liquids below the intraocular temperature and above 0° C. and melt into the conducting liquid at a temperature below intraocular temperature.
[0043] In a fourth aspect, the invention provides an intraocular variable focus implant comprising: a conducting liquid, a non-conducting liquid, a compound forming a solid interface between the non conducting and conducting liquids, and being soluble in the non conducting liquid at the intraocular temperature, a first electrode in contact with the conducting liquid, a second electrode insulated from the conducting liquid, wherein the liquid interface is movable by electrowetting according to a change in a voltage applied between the first and second electrodes.
[0044] In a fifth aspect, the invention provides an intraocular variable focus implant comprising: a conducting liquid, a non-conducting liquid, a compound forming a solid interface between the non conducting and conducting liquids, and being soluble in the conducting liquid at the intraocular temperature, a first electrode in contact with the conducting liquid, a second electrode insulated from the conducting liquid, wherein the liquid interface is movable by electrowetting according to a change in a voltage applied between the first and second electrodes.
[0045] In some embodiments of the first aspect, the invention provides an intraocular variable focus implant wherein a solid interface is formed between conducting and non conducting liquid, said solid interface being soluble in at least one liquid.
BRIEF DESCRIPTION OF DRAWINGS
[0046] FIG. 1 shows an electrowetting based IOL in accordance with one or more embodiments of the claimed invention.
[0047] FIG. 2 shows a schematic view of a process to fill, fold and inject an IOL using a single non-conducting fluid in accordance with one or more embodiments of the invention.
[0048] FIG. 3 shows a schematic view of a process to fill, fold and inject an IOL using two separate non-conducting fluids, both having a melting temperature above intraocular temperature in accordance with one or more embodiments of the invention.
[0049] FIG. 4 shows a schematic view of a process to fill, fold and inject an IOL according to the present invention, using two separate non-conducting fluids, one having a melting temperature below injection temperature, the other one having a melting temperature above injection temperature in accordance with one or more embodiments of the invention.
DETAILED DESCRIPTION
[0050] Specific embodiments of the invention will now be described in detail with reference to the accompanying figures. Like elements in the various figures are denoted by like reference numerals for consistency. Further, the use of “Fig.” in the drawings is equivalent to the use of the term “Figure” in the description.
[0051] In the following detailed description of embodiments of the invention, numerous specific details are set forth in order to provide a more thorough understanding of the invention. However, it will be apparent to one of ordinary skill in the art that the invention may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description.
[0052] Embodiments of the claimed invention relate to an intraocular liquid (IOL) lens that contains two immiscible liquids in contact, without any physical separation between liquids. IOL devices are typically scrolled or folded prior to injection in the eye, to operate as non-invasively as possible. If such an IOL is a liquid lens, the scrolling or folding operation is likely to move liquids out of their confinement area or disperse on liquid in the other due to shear stress and, thus, degrade the performance of the liquid lens. One or more embodiments of the invention relate to a liquid lens and method of manufacturing a liquid lens that remains undisturbed by scrolling or folding.
[0053] European Patent EP1996968 from Varioptic is hereby incorporated by reference in its entirety. EP1996868 describes an IOL based on electrowetting actuation and made of two immiscible liquids standing on an insulating and hydrophobic surface, encapsulated in a foldable structure.
[0054] EP1996968 does not disclose the fluids used in such a IOL device or how to fold the device without disturbing the liquid's confinement. One of the issues associated with IOL devices is the ability of the device to be folded in order to reduce ocular incision. The present invention provides a solution to this technical issue.
[0055] In one or more embodiments of the invention, an IOL device based on electrowetting actuation, containing two immiscible liquids, enables device folding prior to injection into the patient eye without disturbing the liquid's confinement.
[0056] In one or more embodiments of the invention, there are two liquids, one conducting and the other non-conducting. The non-conducting liquid is in a solid state while lens is folded and injected in the patient's eye. Then, the fluid becomes a liquid state once in the patient eye, at intraocular temperature (typically between 33° C. and 37° C. using an ambient air temperature of 20° C.).
[0057] In one or more embodiments of the invention, the non-conducting liquid has a melting temperature below intraocular temperature and above 0° C. In one or more embodiments, the melting temperature of the non-conducting liquid is above 10° C. In one or more embodiments, the melting temperature of the non-conducting liquid is above 20° C.
[0058] Because the non-conducting liquid is solid during folding process, it is unlikely that it will move out of its confinement area, and embodiments of the IOL device in the present invention may be injected through a reduced corneal incision while having an optimized performance.
[0059] In one or more embodiments of the invention, a membrane made of a non-conducting compound, may separate the non-conducting and conducting fluid during the folding and injection process.
[0060] In one or more embodiments of the invention, the conducting liquid has a melting temperature below intraocular temperature and above 0° C. In one or more embodiments, the melting temperature of the conducting liquid is above 10° C. In one or more embodiments, the melting temperature of the conducting liquid is above 20° C.
[0061] In one or more embodiments of the invention, a membrane made of a polar compound, may separate the non-conducting and conducting fluid during the folding and injection process and melt in the conducting fluid below intraocular temperature.
[0062] In one or more embodiments of the invention, either the conducting or non-conducting liquid may include a gelling agent, forming a gel when incorporated, or dissolved, into the liquid, and having a melting temperature below intraocular temperature and above 0° C. In one or more embodiments, the melting temperature of the jellified fluid is above 10° C. In one or more embodiments, the melting temperature of the jellified fluid is above 20° C.
[0063] In one or more embodiments of the invention, the conducting liquid may contain a gelling agent like alginic acid, sodium alginate, potassium alginate, ammonium alginate, calcium alginate, gelatin, furcellaran or polysaccharides like agarose, carrageenan, or pectin.
[0064] FIG. 1 shows an ophthalmic implant as described in European patent application EP1996968, in accordance with one or more embodiments of the claimed invention. The implant is made from transparent and flexible materials, examples include, but are not limited to, transparent polymers like polymethyl methacrylate (PMMA), polycarbonate, epoxies, polyesters, fluoropolymers, fluorinated ethylene propylene (FEP), PTFE (polytetrafluoroethylene), polyolefins, and polycycloolefins. Inside the implant, two liquids are trapped: the first liquid ( 4 ) is a non-polar liquid, non-conducting (or insulating liquid) forming a drop inside the capsule. The second liquid ( 5 ) is a conducting polar liquid (may be based on water solution). Both liquids are immiscible, with approximately the same density, and different indices of refraction. A first electrode ( 11 ) in the shape of a ring may be covered with a thin insulator film ( 2 ) for electrowetting actuation. In the embodiment described in FIG. 1 , the thin insulator film ( 2 ) is also playing the role of the capsule window. A second electrode ( 10 ) is in direct contact with the conducting liquid ( 5 ).
[0065] Electrowetting actuation is used to activate the lens. Using a control signal, a voltage is applied between electrodes ( 10 ) and ( 11 ). The voltage induces an electrowetting effect, thus changing the contact angle of the drop of liquid ( 4 ), passing from shape A (flat drop) to shape B (a more curved drop). Because the indices of refraction of the two liquids are different, the device forms a variable power lens. In one or more embodiment of the invention, the dioptre variation may range from a few dioptres to several tens of dioptres.
[0066] In one or more embodiments of the invention, the non-conducting fluid includes one or more non-conducting compounds with a melting temperature below intraocular temperature, and above the temperature during the injection process. FIG. 2 is a schematic of the process in accordance with one or more embodiments of the invention. Table 1 describes several compounds with corresponding melting temperatures. Examples of specific conducting and non-conducting fluids in accordance with one or more embodiments of the invention are given in formulations 1 and 4 (respectively conducting and non-conducing fluids), formulations 2 and 5, and formulations 3 and 6. However, the claimed invention is not limited to these specific combinations of conducting and non-conduction fluids. The liquid lens may filled with both conducting and non-conducting fluids at a temperature above melting temperature, then cooled until the non-conducting fluid is solidified. IOL may then be scrolled or folded at a temperature below the melting point temperature in preparation for surgery. Once the IOL is within the patient's eye, and unfolded, the non-conducting fluid melts and the liquid lens becomes operational.
[0000]
TABLE 1
List of compounds and corresponding melting temperature
Name
mp (° C.)
Hexadecane
18.1
diphenyl methane
26
Octadécane
27.8
Nonadécane
32.1
Diphenylethane
50
Vinyltriphenylsilane
58
Diphenyl disulfide
58
Palmitic acid
62
1,4-Di-tert-butylbenzene
77
1-Methylfluorene
84
9,10-Dihydroanthracene
105
Fluorene
116
Methyltriphenylsilane
<30
Allyltriphenylsilane
88
Cyclooctane
10
Cyclohexane
6.5
hexadecahydropyrene
<30
Eicosane
41
Cyclododecane
<30
Conducing Fluid Formulation 1
[0067]
[0000]
compound
Weight %
Sodium Bromide
0.86%
water
97.64%
polypropylene glycol
0.50%
1-Pentanol
1.00%
measurement
value
density (g/cm3)
0.9968
refractive index at 589 nm at 20° C.
1.33571
Viscosity at 20° C. (mm 2 /s)
1.5065
Conducing Fluid Formulation 2
[0068]
[0000]
compound
Weight %
Sodium Bromide
1.43%
water
97.07%
polypropylene glycol
0.50%
1-Pentanol
1.00%
measurement
value
density (g/cm3)
1.005
refractive index at 589 nm at 20° C.
1.337
Viscosity at 20° C. (mm 2 /s)
1.040
Conducing Fluid Formulation 3
[0069]
[0000]
Compound
weight %
Sodium Bromide
2.01%
Water
96.49%
polypropylene glycol
1.00%
1-Pentanol
0.50%
Measurement
value
density (g/cm3)
1.0078
refractive index at 589 nm at 20° C.
1.3377
Viscosity at 20° C. (mm 2 /s)
1.0395
Non-Conducing Fluid Formulation 4
[0070]
[0000]
Compound
weight %
Diphenylmethane
90.00%
Diphényldiméthylgermane
5.00%
Hexadecane
5.00%
measurement
value
density (g/cm3)
0.9963
refractive index at 589 nm at 20° C.
1.5701
Viscosity at 20° C. (mm 2 /s)
2.6973
Melting point (° C.)
>15° C.
Non-Conducing Fluid Formulation 5
[0071]
[0000]
compound
weight %
diphenylmethane
91.80%
diphényldiméthylgermane
6.20%
Hexadecane
2.00%
measurement
value
density (g/cm3)
1.0052
refractive index at 589 nm at 20° C.
1.5743
Viscosity at 20° C. (mm 2 /s)
2.6778
Melting point (° C.)
>15° C.
Non-Conducing Fluid Formulation 6
[0072]
[0000]
compound
weight %
diphenylmethane
71.5%
diphényldiméthylgermane
18.5%
Hexadecane
10.0%
measurement
value
density (g/cm3)
1.0083
refractive index at 589 nm at 20° C.
1.5621
Viscosity at 20° C. (mm 2 /s)
2.9330
Melting point (° C.)
15
[0073] In one or more embodiments of the invention, the conducting fluid comprises water and at least one organic or inorganic ion, typically at least one organic or inorganic ionic or ionizable salt, or a mixture thereof, conferring conductive properties to said fluid.
[0074] In the following specification, “ionic salts” refers to salts that are totally or substantially totally dissociated (such as a bromine-anion and a cation) in water. “ionizable salts” refers to salts that are totally or substantially totally dissociated in water, after chemical, physical or physico-chemical treatment.
[0075] Ions that are suitable in the present invention include both cations and anions, which may be simultaneously, but not necessarily, present together in the conducting fluid. Examples of anions include, but are not limited to, halides, e.g. chloride, bromide, iodide, sulphate, carbonate, hydrogen carbonate, acetate, and the like, as well as mixtures thereof. Examples of cations include, but are not limited to alkali, and alkaline-earth.
[0076] Organic and inorganic ionic and ionizable salts are thus well known in the art, and examples of these include, but are not limited to potassium acetate, magnesium chloride, zinc bromide, lithium bromide, sodium bromide, lithium chloride, calcium chloride, sodium sulphate, sodium dibasic phosphate, sodium monobasic phosphate, phosphoric acid, acetic acid, sodium acetate, carboxylic acid (RCOOH, where R being an alkyl group C 2n H 2n+1 , with n being between 1 and 10) and corresponding sodium carboxylate salt, phosphocholine salt and the like, as well as mixtures thereof.
[0077] Mixtures of one or more ionic salts together with one or more ionizable salts are also encompassed by the present invention.
[0078] As already mentioned, the conductive fluid comprises an organic or inorganic ionic or ionizable salt. Said salt is dissolved in water. Water to be used in the conductive fluid should be as pure as possible, i.e. free, or substantially free, of any other dissolved components that could alter the optical properties of the optical electrowetting device, namely an optical lens driven by electrowetting. Ultra pure water is most preferably used. The concentration of the dissolved salt in the conductive fluid may vary in large proportions, keeping in mind a too high concentration may result in undesirable increase of density, refractive index, turbidity, haze, or loss of transparency for the optical device, lens or else.
[0079] In one or more embodiments of the invention, the non-conducting fluid is a mixture of compounds, where at least one compound has a melting temperature above intraocular temperature, but the mixture thereof has a melting temperature below intraocular temperature. This is possible because most liquids have a melting temperature depression when mixed with other compounds, when all compounds are miscible. FIG. 3 shows a schematic of the process in accordance with one or more embodiments of the invention. Compounds having the highest melting temperature may be injected in the liquid lens at a temperature above its melting temperature then cooled to a temperature above melting point of the next compound to be injected. At this stage, the injected compounds may have been solidified as a result of the cooling. Therefore, all compounds may be injected separately. The order of injection may be from the highest melting point to the lowest melting point. When the last compound is injected, the IOL may be cooled until the non-conducting fluid is fully solidified. IOL may be folded at temperature below melting point temperature and is ready for the surgery operation. Once the IOL is within the patient eye, and unfolded, the non-conducting fluid compounds melt, mix together, and liquid lens becomes operational. One specific example of the above embodiment is the formulation 1 and 7; however, the above embodiment is not limited as such.
Non-Conducing Fluid Formulation 7
[0080]
[0000]
compound
weight %
diphenylmethane
81.00%
Vinyltriphenylsilane
14.00%
Cyclodecane
5.00%
measurement
value
density (g/cm3)
0.9978
[0081] FIG. 4 is a schematic of a process to fill, fold and inject an IOL using two separate non-conducting fluids, where one has a melting temperature (MP#2) below injection temperature and the other has a melting temperature (MP#1) above injection temperature, but below the intraocular temperature in accordance with one or more embodiments of the invention. The fluid having the lowest melting temperature, below injection temperature, is injected in the liquid lens at a temperature above its melting temperature, and then cool down until solidification. That fluid is kept at a temperature below melting temperature of the other compounds. Then a fluid having a melting temperature between the injection temperature and the intraocular temperature is injected and, thus, solidified at the surface of the first injected compounds. Therefore, in accordance with one or more embodiments of the invention, the fluids may be injected separately with the fluid having the highest melting temperature physically located at the interface between the conducting fluid and the other non-conducting fluid. Examples of the conducting and non-conducting fluids that may be used include, but are not limited to, the formulations 1 and 8 and formulations 3 and 9.
Non-Conducing Fluid Formulation 8
[0082]
[0000]
compound
weight %
Phenyltrimethylgermane
55%
SIP 6827,0
25%
Hexadecane
20%
measurement
value
density (g/cm3)
0.9980
refractive index at 589 nm at 20° C.
1.4744
Viscosity at 20° C. (mm 2 /s)
1.8834
Non-Conducing Fluid Formulation 9
[0083]
[0000]
compound
weight %
diphényldiméthylgermane
52.50%
SIP 6827,0
17.50%
Hexadecane
30.00%
measurement
value
density (g/cm3)
1.0080
refractive index at 589 nm at 20° C.
1.5067
Viscosity at 20° C. (mm 2 /s)
4.0537
[0084] In one or more embodiment of the present invention, the non conducting fluid is injected in the liquid lens at a temperature above its melting temperature, and then cool down until solidification. A further compound is then deposited on the solidified non-conducting fluid prior to the conducting fluid injection to form a solid membrane. The membrane remains solid during the folding process and injection but is soluble in the conducting or the non-conducting fluid at intraocular temperature after injection in the patient's eye.
[0085] In one or more embodiment of the present invention, the solid membrane is made of water soluble polymers like hydroxyethylcellulose, ethylcellulose polymers, cellulose ethers, Poly(Acrylic Acids), Polyvinyl alcohol, or water soluble resins, or hydrocarbon soluble polymers.
[0086] In one or more embodiment of the present invention, the solid membrane formed between the conducting and non conducting fluids is made soluble in fluids by irradiation during the capsulotomy operation.
[0087] The IOL may then be folded at temperature below melting point temperature of the compounds at the interface and warmed up at the injection temperature. The fluid at the interface may act as a membrane between the conducting fluid and the other non-conducting fluid that has a melting temperature below the injection temperature. At this point, the IOL is ready for surgical implantation. Once the IOL is within the patient's eye and unfolded, the non-conducting fluids may melt and mix together. At this point, the liquid lens becomes operational.
[0088] In one or more embodiments of the invention, the insulating coating may be made of poly-para-xylylene linear polymers, for example, Parylene C; Parylene N, Parylene VT4, and Parylene HT.
[0089] In one or more embodiments of the invention, the insulating coating may be coated with a thin layer of a low surface energy coating such as Teflon® or Fluoropel®.
[0090] Table 1 is a list of compounds that may be used in the present invention.
[0091] In one or more embodiments of the invention, the non conductive fluid may contain a linear alkane (C n H 2n+2 , where 22>n>15, such as hexadecane, nonadecane, eicosane), a diphenyl alkane (C 2 H 2n —(C 6 H 5 ) 2 , where 5>n>1, such as diphenylmethane, diphenylethane), or vinyl triphenylsilane.
[0092] In one or more embodiments of the invention, the non-conductive fluid may contain one or more of the following specific compounds: diphenylsulfide, palmitic acid, 1,4-Di-ter-butylbenzene, 1-methylfluorene, 9,10-Dihydroanthracene, and Fluorene.
[0093] In one or more embodiments, the non-conductive fluid may contain one or more cycloalkane C n H 2n , where 6<n<15, such as cyclooctane, cyclohexane, or cyclododecane.
[0094] In one or more embodiments, the non-conductive fluid may contain one or more organosilanes of formula Si—(R) 4 , where at least three of the R groups are represented independently by (hetero)aryl, (hetero)arylalkyl, (hetero)arylalkenyl and (hetero)arylalkynyl. In such embodiments, the at least one of the R groups may be an alkyl (C n H 2n+1 ) or alkene group (C n H 2n−1 ), where n=1, 2 or 3. Examples include, but are not limited to methyltriphenylsilane, allyltriphenylsilane, and ethyltriphenylsilane.
[0095] The non-conductive fluid may contain one or more germane based species, for example hexamethyldigermane, diphenyldimethylgermane, and phenyltrimethyl-germane.
[0096] Table 2 describes mixtures of compounds depending on temperature and indicates when mixture is in solid and liquid state in accordance with one or more embodiments of the invention. The solid state should be used during folding and injection. In particular Table 2 demonstrates that a small amount of compound having a very low melting temperature (for example <20° C. for phenyltrimethyl germane) mixed with a large amount of a high melting temperature compound (for example diphenylmethane) will result in a mixture with a melting temperature in the required range, i.e. between 10° C. and 32° C.
[0000]
TABLE 2
State diagram for various mixtures of non conducting fluids (solid: S; Liquid: L)
Composition
−20° C.
−2° C.
+10° C.
+15° C.
+18° C.
+25° C.
Diphenylmethane
S
S
S
S
S
S
10% phenylgermane + 90% diphenylmethane
S
S
S
S + L
S + L
L
30% phenylgermane + 70% diphenylmethane
S
S + L
S + L
L
L
L
70% phenylgermane + 30% diphenylmethane
S + L
S + L
S + L
L
L
L
Phenylgermane
L
L
L
L
L
L
5% diphenylgermane + 95% diphenylmethane
S
S
S
S + L
S + L
L
10% diphenylgermane + 90% diphenylmethane
S
S
S + L
S + L
S + L
L
20% diphenylgermane + 80% diphenylmethane
S
S
S + L
S + L
S + L
L
formulation 4
S
S
S
S + L
S + L
L
formulation 6
S
S
S
S + L
L
L
[0097] Embodiments of the invention may be used in any application that using a device containing two immiscible liquids, such that the liquids are contact with each other, and the device is folded during the application at a given temperature, and then unfolded at another temperature above the first temperature, where the liquids must be confined in a given volume, when the performance of the device may be disturbed and/or lowered if liquids are temporarily mixed during the folding and unfolding process.
[0098] 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. Accordingly, the scope of the invention should be limited only by the attached claims. | According to a first aspect, the invention relates to an intraocular variable focus implant comprising a non-conducting liquid with a melting temperature above 0° C., a conducting liquid, a liquid interface formed by the non-conducting and conducting liquids, a first electrode in contact with the conducting liquid, a second electrode insulated from the conducting liquid, wherein the liquid interface is movable by electro wetting according to a change in a voltage applied between the first and second electrodes. | 54,647 |
[0001] This nonprovisional application claims the benefit of U.S. provisional application No. 60/174,601 entitled “Map Decoding In Channels With Memory” filed on Jan. 5, 2000. The Applicant of the provisional application is William Turin (Attorney Docket No. 105038). The above provisional application is hereby incorporated by reference including all references cited therein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] This invention relates to iterative decoding of input sequences.
[0004] 2. Description of Related Art
[0005] Maximum a posteriori (MAP) sequence decoding selects a most probable information sequence X 1 T =(X 1 , X 2 , . . . , X T ) that produced the received sequence Y 1 T =(Y 1 , Y 2 , . . . , Y T ). For transmitters and/or channels that are modeled using Hidden Markov Models (HMM), the process for obtaining the information sequence X 1 T that corresponds to a maximum probability is difficult due to a large number of possible hidden states as well as a large number of possible information sequences X 1 T . Thus, new technology is needed to improve MAP decoding for HMMs.
SUMMARY OF THE INVENTION
[0006] This invention provides an iterative process to maximum a posteriori (MAP) decoding. The iterative process uses an auxiliary function which is defined in terms of a complete data probability distribution. The MAP decoding is based on an expectation maximization (EM) algorithm which finds the maximum by iteratively maximizing the auxiliary function. For a special case of trellis coded modulation, the auxiliary function may be maximized by a combination of forward-backward and Viterbi algorithms. The iterative process converges monotonically and thus improves the performance of any decoding algorithm.
[0007] The MAP decoding decodes received inputs by minimizing a probability of error. A direct approach to achieve this minimization results in a complexity which grows exponentially with T, where T is the size of the input. The iterative process avoids this complexity by converging on the MAP solution through repeated use of the auxiliary function.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The invention is described in detail with reference to the following figures where like numerals reference like elements, and wherein:
[0009] [0009]FIG. 1 shows a diagram of a communication system;
[0010] [0010]FIG. 2 shows a flow chart of an exemplary iterative process;
[0011] [0011]FIGS. 3-6 show state trajectories determined by the iterative process;
[0012] [0012]FIG. 7 shows an exemplary block diagram of the receiver shown in FIG. 1;
[0013] [0013]FIG. 8 shows a flowchart for an exemplary process of the iterative process for a TCM example; and
[0014] [0014]FIG. 9 shows step 1004 of the flowchart of FIG. 8 in greater detail.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0015] [0015]FIG. 1 shows an exemplary block diagram of a communication system 100 . The communication system 100 includes a transmitter 102 , a channel 106 and a receiver 104 . The transmitter 102 receives an input information sequence I 1 T (i.e., I 1 , I 2 , . . . , I T ) of length T, for example. The input information sequence may represent any type of data including analog voice, analog video, digital image, etc. The transmitter 102 may represent a speech synthesizer, a signal modulator, etc.; the receiver 104 may represent a speech recognizer, a radio receiver, etc.; and the channel 106 may be any medium through which the information sequence X 1 T (i.e., X 1 , X 2 , . . . , X T ) is conveyed to the receiver 104 . The transmitter 102 may encode the information sequence I 1 T and transmit encoded information sequence X 1 T through the channel 106 and the receiver 104 receives information sequence Y 1 T (i.e., Y 1 , Y 2 , . . . , Y T ). The problem in communications is, of course, to decode Y 1 T in such a way as to retrieve I 1 T .
[0016] Maximum a posteriori (MAP) sequence decoding is a technique that decodes the received sequence Y 1 T by minimizing a probability of error to obtain X 1 T (and if a model of the transmitter 102 is included, to obtain I 1 T ). In MAP, the goal is to choose a most probable X 1 T that produces the received Y 1 T . The MAP estimator may be expressed by equation 1 below.
X ^ 1 T = arg max X 1 T Pr ( X 1 T , Y 1 T ) ( 1 )
[0017] where Pr(·) denotes a corresponding probability or probability density function and {circumflex over (X)} 1 T is an estimate of X 1 T . Equation 1 sets {circumflex over (X)} 1 T to the X 1 T that maximizes Pr(X 1 T ,Y 1 T ). The Pr (X 1 T , Y 1 T ) term may be obtained by modeling the channel 106 of the communication system 100 using techniques such as Hidden Markov Models (HMMs). An input-output HMM λ=(S,X,Y,π,{P(X,Y)}) is defined by its internal states S={1,2, . . . n}, inputs X, outputs Y, initial state probability vector π, and the input-output probability density matrices (PDMs) P(X,Y), XεX, YεY. The elements of P(X,Y), p ij (X,Y)=Pr(j,X,Y|i), are conditional probability density functions (PDFs) of input x and corresponding output y after transferring from the state i to state j. It is assumed that the state sequence S 0 t =(S 0 , S 1 , . . . , S t ), input sequence X 1 t =(X 1 ,X 2 , . . . X t ), and output sequence Y 1 t =(Y 1 ,Y 2 , . . . , Y t ) possess the following Markovian property
Pr(S t , X t , Y t |S 0 t−1 , X 1 t−1 , Y 1 t−1 )═Pr(S t , X t , Y t |S t−1 ).
[0018] Using HMM, the PDF of the input sequence X 1 T and output sequence Y 1 T may be expressed by equation 2 below:
p T ( X 1 T , Y 1 T ) = π ∏ i = 1 T P ( X i , Y i ) 1 ( 2 )
[0019] where 1 is a column vector of n ones, π is a vector of state initial probabilities, and n is a number of states in the HMM. Thus, the MAP estimator when using HMM may be expressed by equation 3 below:
X ^ 1 T = arg max X 1 T [ π ∏ i = 1 T P ( X i , Y i ) 1 ] ( 3 )
[0020] The maximization required by equation 3 is a difficult problem because all possible sequences of X 1 T must be considered. This requirement results in a complexity that grows exponentially with T. This invention provides an iterative process to obtain the maximum without the complexity of directly achieving the maximization by evaluating equation 2 for all possible X 1 T , for example. In the iterative process, an auxiliary function is developed whose iterative maximization generates a sequence of estimates for X 1 T approaching the maximum point of equation 2.
[0021] The iterative process is derived based on the expectation maximization (EM) algorithm. Because the EM algorithm converges monotonically, the iterative process may improve the performance of any decoding algorithm by using its output as an initial sequence of the iterative decoding algorithm. In the following description, it is assumed that HMM parameters for the channel 106 and/or the transmitter 102 are available either by design or by techniques such as training.
[0022] The auxiliary function may be defined in terms of a complete data probability distribution shown in equation 4 below.
Ψ ( z , X 1 T , Y 1 T ) = π i o ∏ i = 1 T p i t - 1 i t ( X t , Y t ) , ( 4 )
[0023] where z=i 0 T is an HMM state sequence, π i 0 is an initial probability vector for state i 0 , and p ij (X,Y) are the elements of the matrix P(X,Y). The MAP estimator of equation 1 can be obtained iteratively by equations 5-9 as shown below.
X 1 , p + 1 T = arg max X 1 T Q ( X 1 T , X 1 , p T ) , p = 0 , 1 , 2 , … ( 5 )
[0024] where p is a number of iterations and Q(X i t , X i,p t ) is the auxiliary function which may be expressed as
Q ( X 1 T , X 1 , p T ) = ∑ z Ψ ( z , X 1 , p T , Y 1 T ) log ( Ψ ( z , X 1 T , Y 1 T ) ) . ( 6 )
[0025] The auxiliary function may be expanded based on equation 4 as follows:
Q ( X 1 T , X 1 , p T ) = ∑ t = 1 T ∑ i = 1 n ∑ j = 1 n γ t , ij ( X 1 , p T ) log ( p ij ( X t , Y t ) ) + C ( 7 )
[0026] where C does not depend on X 1 T , n is a number of states in the HMM and
γ t,ij (X 1,p T )=α i (X 1,p t−1 , Y 1 t−1 ) p ij (X t,p , Y t )β j (X t+1,p T , Y t+1 T ) (8)
[0027] where α i (X 1,p t , Y 1 t ) and β j (X t+1,p T , Y t+1 T )are the elements of the following forward and backward probability vectors
α ( X 1 t , Y 1 t ) = π ∏ i = 1 T P ( X i , Y i ) , and
β ( X t + 1 T , Y t + 1 T ) = ∏ i = t + 1 T P ( X i , Y i ) 1. ( 9 )
[0028] Based on equations 5-9, the iterative process may proceed as follows. At p=0, an initial estimate of X t,0 T is generated. Then, Q(X 1 T ,X 1,0 T ) is generated for all possible sequences of X 1 T . From equations 7 and 8, Q(X 1 T , X 1,0 T ) may be evaluated by generating γ t,ij (X 1,0 T ) and log (p ij (X t , Y t )) for each t, i, and j. γ t,ij (X 1,0 T ) may be generated by using the forward-backward algorithm as shown below:
α(X 1,p 0 , Y 1 0 )=π, α(X 1,p t , Y 1 t )=α(X 1,p t−1 , Y 1 t−1 )P(X t,p , Y t ), t= 1,2, . . . T
β(X T+1,p T , Y T+1 T )=1, β(X t,p T , Y t T )═P(X t,p , Y t )β(X t+1,p T , Y t+1 T ), t=T− 1, T− 2, . . . ,1
[0029] Log (p ij (X t ,Y t )) is generated for all possible X t for t=1, 2, . . . , T and the (X t )s that maximize D(X 1 T , X 1,0 T ) are selected as X 1,1 T . After X 1,1 T is obtained, it is compared with X 1,0 T . If a measure D(X 1,1 T , X 1,0 T ) of difference between the sequences exceeds a compare threshold, then the above process is repeated until the difference measure D(X 1,p T , X 1,p−1 T ) is within the threshold. The last X 1,p T for p iterations is the decoded output. The measure of difference may be an amount of mismatch information. For example, if X 1 T is a sequence of symbols, then the measure may be a number of different symbols between X 1,p T and X 1,p−1 T (Hamming distance); if X 1 T is a sequence of real numbers, then the measure may be an Euclidean distance D(X 1,p T , X 1,p−1 T )=[Σ i=1 T (X i,p −X i,p−1 ) 2 ] 1/2 .
[0030] [0030]FIG. 2 shows a flowchart of the above-described process. In step 1000 , the receiver 104 receives the input information sequence Y 1 T and goes to step 1002 . In step 1002 , the receiver 104 selects an initial estimate for the decode output information sequence X 1,0 T and goes to step 1004 . In step 1004 , the receiver 104 generates γ t,ij (X 1,p T ) where p=0 for the first iteration and goes to step 1006 . In step 1006 , the receiver 104 generates all the log (p ij (X t , Y t )) values and goes to step 1008 .
[0031] In step 1008 , the receiver 104 selects a sequence X 1,p+1 T that maximizes Q(X 1,p+1 T , X 1,p T ) and goes to step 1010 . In step 1010 , the receiver 104 compares X 1,p T with X 1,p+1 T . If the compare result is within the compare threshold, then the receiver 104 goes to step 1012 ; otherwise, the receiver 104 returns to step 1004 and continues the process with the new sequence X 1,p+1 T . In step 1012 , the receiver 104 outputs X 1,p+1 T and goes to step 1014 and ends the process.
[0032] The efficiency of the above described iterative technique may be improved if the transmitted sequence is generated by modulators such as a trellis coded modulator (TCM). A TCM may be described as a finite state machine that may be defined by equations 10 and 11 shown below.
S t+1 =f t (S t , I t ) (10)
X t =g t (S t , I t ) (11)
[0033] Equation 10 specifies the TCM state transitions while equation 11 specifies the transmitted information sequence based on the state and the input information sequence. For example, after receiving input I t in state S t , the finite state machine transfers to state S t+1 based on S t and I t as shown in equation 10. The actual output by the transmitter 102 is X t according to equation 11. Equation 10 may represent a convolutional encoder and equation 11 may represent a modulator. For the above example, the transmitter output information sequence X 1 T may not be independent even if the input information sequence I 1 T is independent.
[0034] In equation 15, the log(p ij (Y t ,X t )) term may be analyzed based on the TCM state transitions because the information actually transmitted X t is related to the source information I t by X t =g t (S t , I t ). This relationship between X t and I t forces many elements p ij (Y t ,X t ) of P (Y t ,X t ), to zero since the finite state machine (equations 10 and 11) removes many possibilities that otherwise must be considered. Thus, unlike the general case discussed in relation to equations 5-9, evaluation of p ij (Y t ,X t ) may be divided into a portion that is channel related and another portion that is TCM related. The following discussion describes the iterative technique in detail for the TCM example.
[0035] For a TCM system with an independent and identically distributed information sequence, an input-output HMM may be described by equations 12 and 13 below.
P(X t , Y t )=└ p s t s t+1 P c (X t |Y t )┘, (12)
[0036] where
p S t S t + 1 = { Pr ( I t ) 0 if S t + 1 = f t ( S t , I t ) otherwise ( 13 )
[0037] P c (Y t |X t ) is the conditional PDM of receiving Y t given that X t has been transmitted for the HMM of a medium (channel) through which the information sequence is transmitted; p s t s t+1 is the probability of the TCM transition from state S t to state S t+1 , and Pr(I t ) is the probability of an input I t . Thus, equation 2 may be written as
p T ( I 1 T , Y 1 T ) = π c ∏ i = 1 T p s t s t + 1 P c ( Y t | X t ) 1 ,
[0038] where π c is a vector of the initial probabilities of the channel states, X t =g t (S t ,I t ), and the product is taken along the state trajectory S t+1 =f t (S t ,I t ) for t=1, 2, . . . , T.
[0039] If all elements of the input information sequence are equally probable, then the MAP estimate may be expressed by equation 14 below.
I ^ 1 T = arg max I 1 T π c ∏ t = 1 T P c ( Y t X t ) 1 , ( 14 )
[0040] The auxiliary function may be expressed by equations 15-17 below corresponding to equations 7-9 above.
Q ( I 1 T , I 1 , p T ) = ∑ t = 1 T ∑ i = 1 n ∑ j = 1 n γ t , ij ( I 1 , p T ) log ( p ij ( Y t X t ) ) + C ( 15 )
[0041] where X t =g t (S t ,I t ) and
γ t,ij (I 1,p T )=α i (Y 1 t−1 |I 1,p t ) p c,ij (Y t |X t,p )β j (Y t+1,p T |I t+1,p T ) (16)
[0042] α i (Y 1 T−1 |I 1,p t−1 ) and β j (Y t+1,p T |I t′1,p T ) are the elements of the forward and backward probability vectors
α ( Y 1 t I 1 t ) = π c ∏ i = 1 t P c ( Y i X i ) and
β ( Y t + 1 T I t + 1 T ) = ∏ i = t + 1 T P c ( Y i X i ) 1 ( 17 )
[0043] From equation 15, the Viterbi algorithm may be applied with the branch metric
m ( I t ) = ∑ i = 1 n ∑ j = 1 n γ t , ij ( I 1 , p T ) log p c , ij ( Y t X t ) , t = 1 , 2 , … , T ( 18 )
[0044] to find a maximum of Q(I 1 T , I 1,p T ) which can be interpreted as a longest path leading from the initial zero state to one of the states S T where only the encoder trellis is considered. The Viterbi algorithm may be combined with the backward portion of the forward-backward algorithm as follows.
[0045] 1. Select an initial source information sequence I 1,0 T =I 1,0 , I 2,0 , . . . , I T,0
[0046] 2. Forward part:
[0047] a. set α(Y 1 0 |I 1 0 )=π, where π is an initial state probability estimate; and
[0048] b. for t=1, 2, . . . , T, compute X t,p =g t (S t ,I t,p ),
α(Y 1 t |I 1,p t )=α(Y 1 t−1 |I 1,p t−1 )P c (Y t |X 1,p ),
[0049] where I 1,p t is a prior estimate of I 1 t .
[0050] 3. Backward part:
[0051] a. set β(Y T+1 T |I T+1,p T )=1 and last state transition lengths L(S T ) to 0 for all the states;
[0052] for t=T,T−1, . . . , 1 compute:
[0053] b. X t =g t (S t ,I t ),
[0054] c. γ t,ij (I 1,p T )=α i (Y 1 t−1 |I 1,p t−1 )p c,j (Y t |X t,p )β j (Y t+1 T |I t+1,p T ),
[0055] d.
L ( S t ) = max I t { L ⌊ f t ( S t , I t ) ⌋ + m ( I t ) } .
[0056] This step selects the paths with the largest lengths (the survivors).
[0057] e.
I ^ t ( S t ) = arg max I t { L [ f t ( S t , I t ) ] + m ( I t ) } .
[0058] This step estimates I t corresponding to the state S t by selecting the I t of the survivor in step d.
[0059] β(Y t T , I t,p T )=P c (Y t |X t,p )β(Y t+1 T |X t+1,p T ).
[0060] g. End (of “for” loop).
[0061] 4. Reestimate the information sequence:
I t,p+1 =Î 1 (Ŝ t ), Ŝ t+1 =f t (Ŝ t ,I t,p+1 ), t= 1,2, . . . , T where Ŝ 1 =0; and
[0062] 5. If I t,p+1 ≠I t,p , go to step 2; otherwise decode the information sequence as I t,p+1 T .
[0063] [0063]FIGS. 3-6 show an example of the iterative process discussed above where there are four states in the TCM and T=5. The dots represent possible states and the arrows represent a state trajectory that corresponds to a particular information sequence. The iterative process may proceed as follows. First, an initial input information sequence I 1,0 5 is obtained. I 1,0 5 may be the output of an existing decoder or may simply be a guess.
[0064] The Viterbi algorithm together with the backward algorithm may be used to obtain a next estimate of the input information sequence I 1,1 5 . This process begins with the state transitions between t=4 and t=5 by selecting state transitions leading to each of the states s0-s3 at t=4 from states at t=5 that have the largest value of the branch metric L(S 4 )=m(I 5 ) of equation 18 above. Then, the process moves to select state transitions between the states at t=3 and t=4 that have the largest cumulative distance L(S 3 )=L(S 4 )+m(I 4 ). This process continues until t=0 and the sequence of input information I 1 5 corresponding to the path connecting the states from t=0 to t=5 that has the longest path
L ( S 0 ) = ∑ t = 1 5 m ( I t )
[0065] is selected as the next input information sequence I 1,1 5 .
[0066] For the example in FIG. 3, state transitions from the states at t=4 to all the states at t=5 are considered. Assuming that the (I t )s are binary, then only two transitions can emanate from each of the states at t=4: one transition for I 5 =0 and one transition for I 5 =1. Thus, FIG. 3 shows two arrows terminating on each state at t=4 (arrows are “backwards” because the backward algorithm is used). State transitions 301 and 302 terminate at state s0; state transitions 303 and 304 terminate at state s1; state transitions 305 and 306 terminate at state s2; and state transitions 307 and 308 terminate at state s3.
[0067] The branch metric m(I t ) of equation 18 represents a “distance” between the states and is used to select the state transition that corresponds to the longest path for each of the states s0-s3 at t=4:
m ( I 5 ) = ∑ i ∑ j γ 5 , ij ( X 1 , 0 5 ) log p ij ( X 5 , Y 5 ) = ∑ i ∑ j α i ( X 1 , 0 4 , Y 1 4 ) p ij ( X 5 , 0 , Y 5 ) β j ( X 6 , 0 5 , Y 6 5 ) log p ij ( Y 5 X 5 ) , ( 19 )
[0068] where β j (X 6.0 5 , Y 6 5 )=1, and X 5 =g 5 (S 5 , I 5 ) by definition. There is an I 5 that corresponds to each of the state transitions 301 - 308 . For this example, L(S 4 )=m(I 5 ) corresponding to odd numbered state transitions 301 - 307 are greater than that for even numbered state transitions 302 - 308 . Thus, odd numbered state transitions are “survivors.” Each of them may be part of the state trajectory that has the longest path from t=0 to t=5. This transition (the survivor) is depicted by the solid arrow while the transitions with smaller lengths are depicted by dashed lines.
[0069] The state sequence determination process continues by extending the survivors to t=3 as shown in FIG. 4 forming state transitions 309 - 316 . The distance between state transitions for each of the states are compared based on L(S 4 )+m(I 4 ), where m(I 4 ) is shown in equation 20 below.
m ( I 4 ) = ∑ i ∑ j γ 5 , ij ( X 1 , 0 5 ) log p ij ( X 4 , Y 4 ) = ∑ i ∑ j α i ( X 1 , 0 3 , Y 1 3 ) p ij ( X 4 , 0 , Y 4 ) β j ( X 5 , 0 , Y 5 ) log p ij ( Y 4 X 4 ) . ( 20 )
[0070] For this example, the distances corresponding to the odd numbered state transitions 309 - 315 are longer than distances corresponding to even numbered state transitions 310 - 316 . Thus, the paths corresponding to the odd numbered state transitions are the survivors. As shown in FIG. 4, the state transition 301 is not connected to any of the states at t=3 and thus is eliminated even though it was a survivor. The other surviving state transitions may be connected into partial state trajectories. For example, partial state trajectories are formed by odd numbered state transitions 307 - 309 , 303 - 311 , 303 - 313 and 305 - 315 .
[0071] The above process continues until t=0 is reached as shown in FIG. 5 where two surviving state trajectories 320 - 322 are formed by the surviving state trajectories. All the state trajectories terminate at state zero for this example because, usually, encoders start at state zero. As shown in FIG. 6, the state trajectory that corresponds to the longest cumulative distance is selected and the input information sequence I 1 5 (via S t+1 =f t (S t ,I t ) that corresponds to the selected trajectory is selected as the next estimated input information sequence Î 1,1 5 . For this example, the state trajectory 320 is selected and the input information sequence I 1 5 corresponding to the state trajectory 320 is selected as Î 1,1 5 .
[0072] [0072]FIG. 7 shows an exemplary block diagram of the receiver 104 . The receiver 104 may include a controller 202 , a memory 204 , a forward processor 206 , a backward processor 208 , a maximal length processor 210 and an input/output device 212 . The above components may be coupled together via a signal bus 214 . While the receiver 104 is illustrated using a bus architecture, any architecture may be suitable as is well known to one of ordinary skill in the art.
[0073] All the functions of the forward, backward and maximal length processors 206 , 208 and 210 may also be performed by the controller 202 which may be either a general purpose or special purpose computer (e.g., DSP). FIG. 7 shows separate processors for illustration only. The forward, backward maximal length processors 206 , 208 and 210 may be combined and may be implemented by using ASICs, PLAs, PLDs, etc. as is well known in the art.
[0074] The forward processor 206 generates the forward probability vectors α i (X 1,p t−1 , Y 1 t−1 ) herein referred to as α i . For every iteration, when a new X 1,p T (or I 1,p T ) is generated, the forward processor 206 may generate a complete set of α i .
[0075] The backward processor 208 together with the maximal length processor 210 generate a new state sequence by searching for maximal length state transitions based on the branch metric m(I t ). Starting with the final state transition between states corresponding to t=T−1 and t=T, the backward processor generates ⊕(X t+1,p T , Y t+1 T ) (hereinafter referred as β j ) as shown in equation 8 for each state transition.
[0076] The maximal length processor 210 generates m(I t ) based on the results of the forward processor 206 , the backward processor 208 and p ij (X t ,Y t ). After generating all the m(I t )s corresponding to each of the possible state transitions, the maximal length processor 210 compares all the L(S t )+m(I t )s and selects the state transition that corresponds to the largest L(S t )+m(I t ), and the I t (via S t+ =f t (S t , I t )) that corresponds to the selected state transition is selected as the estimated input information for that t. The above process is performed for each t=1, 2, . . . , T to generate a new estimate I 1,p T for each of the iteration p.
[0077] Initially, the controller 202 places an estimate of the PDM P(X,Y) and π in the memory 204 that corresponds to the HMM for the channel 106 and/or the transmitter 102 . The PDM P(X,Y) may be obtained via well known training processes, for example.
[0078] When ready, the controller 202 receives the received input information sequence Y 1 T and places them in the memory 204 and selects an initial estimate of I 1,0 T (or X 1,0 T ). The controller 202 coordinates the above-described iterative process until a new estimate I 1,1 T (or X 1,1 T ) is obtained. Then, the controller 202 compares I 1,0 T with I 1,1 T to determine if the compare result is below the compare threshold value (e.g., matching a predetermined number of elements or symbols of the information sequence). The compare threshold may be set to 0, in which case I 1,0 T must be identical with I 1,1 T . If an acceptable compare result is reached, I 1,1 T is output as the decoded output. Otherwise, the controller 202 iterates the above-described process again and compares the estimated I 1,p T with I 1,p−1 T until an acceptable result is reached and I 1,p T is output as the decoded output.
[0079] [0079]FIG. 8 shows a flowchart of the above-described process. In step 1000 , the controller 202 receives Y 1 T via the input/output device 212 and places Y 1 T in the memory 204 and goes to step 1002 . In step 1002 , the controller 202 selects an initial estimate for I 1,0 T and goes to step 1004 . In step 1004 , the controller 202 determines a new state sequence and a next estimated I 1,1 T (I 1,p T , where p=1) (via the forward, backward and maximal length processors 206 , 208 and 210 ) and goes to step 1006 . In step 1006 , the controller 202 compares I 1,0 T with I 1,1 T . If the compare result is within the predetermined threshold, then the controller 202 goes to step 1008 ; otherwise, the controller 202 returns to step 1004 . In step 1008 , the controller 202 outputs I 1,p T where p is the index of the last iteration and goes to step 1010 and ends the process.
[0080] [0080]FIG. 9 shows a flowchart that expands step 1004 in greater detail. In step 2000 , the controller 202 instructs the forward processor 206 to generate α i as shown in equation 8, and goes to step 2002 . In step 2002 , the controller 202 sets the parameter t=T and goes to step 2004 . In step 2004 , the controller 202 instructs the backward processor 208 to generate β j and the maximal length processor 210 to determine next set of survivors based on equation 18 and time t+1 survivors and goes to step 2006 .
[0081] In step 2006 , the controller 202 decrements t and goes to step 2008 . In step 2008 , the controller 202 determines whether t is equal to 0. If t is equal to 0, the controller 202 goes to step 2010 ; otherwise, the controller 202 returns to step 2004 . In step 2010 , the controller 202 outputs the new estimated I 1 T and goes to step 2012 and returns to step 1006 of FIG. 5.
[0082] A specific example of the iterative process for convolutional encoders is enclosed in the appendix.
[0083] While this invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, preferred embodiments of the invention as set forth herein are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention.
[0084] For example, a channel may be modeled as P c (Y|X)=P c B c (Y|X) where P c is a channel state transition probability matrix and B c (Y|X) is a diagonal matrix of state output probabilities. For example, based on the Gilbert-Elliott model
B c ( X X ) = [ 1 - b 1 0 0 1 - b 2 ] and B c ( X _ X ) = [ b 1 0 0 b 2 ] ,
[0085] where {overscore (X)} is the complement of X. For this case, m(I t ) may be simplified as
m ( I t ) = ∑ i = 1 n c γ t , i ( I 1 , p T ) b j ( Y t | X t ) , t = 1 , 2 , … , T , and
[0086] and γ t,i (I 1,p T )=α i (Y 1 t |I 1,p t )β i (Y t+1 T |I t+1,p T ), where b j (Y t |X t ) are the elements of B c . | This invention provides an iterative process to maximum a posteriori (MAP) decoding. The iterative process uses an auxiliary function which is defined in terms of a complete data probability distribution. The auxiliary function is derived based on an expectation maximization (EM) algorithm. For a special case of trellis coded modulators, the auxiliary function may be iteratively evaluated by a combination of forward-backward and Viterbi algorithms. The iterative process converges monotonically and thus improves the performance of any decoding algorithm. The MAP decoding minimizes a probability of error. A direct approach to achieve this minimization results in complexity which grows exponentially with T, where T is the size of the input. The iterative process avoids this complexity by converging on the MAP solution through repeated maximization of the auxiliary function. | 35,433 |
FIELD OF THE INVENTION
The present invention relates to the field of document processing in text editing systems and more specifically to processing (e.g., creating, inserting, editing, deleting, and formatting) of a document (e.g., an RPG document) in a first system (e.g., Unicode environment) targeted for another system (e.g., non-Unicode).
BACKGROUND
As computer operating environments have evolved, a number of character encoding schemes have been developed to account for varying linguistics requirements. Character encoding schemes such as SBCS (Single-Byte Character Set), DBCS (Double-Byte Character Set) and MBCS (Multi-Byte Character Set) have been widely utilized to support unique character schemes. The range of encoding schemes has resulted in inter-operability issues such as document conversion errors when converting documents to different unique character sets supported by each computer operating environment. In order to address the problems that have resulted from maintaining unique character encoding schemes, the Unicode character encoding was developed as a single character encoding scheme and has become a standard for many current operating environments.
The proliferation of newer computer operating environments based on the Unicode character encoding scheme, and the fact that a large number of computer operating environments and programs still utilize non-Unicode (SBCS, DBCS, MBCS) encoding schemes, has created technical challenges when programs and documents are transferred between different types of computer operating environments.
One such challenge arises when documents from structured programming languages such as RPG (Report Program Generator), DDS (Data Description Specification) and COBOL (Common Business Oriented Language) are converted between Unicode and non-Unicode encoding schemes. The process of document conversion between the encoding schemes, can impact the integrity of field definitions and data contained within the fields, which are executed and utilized by a programming language such as RPG. The field definitions are important to the proper execution of programming languages and the integrity of the data contained within them must be maintained. Similar difficulties arise when a document (e.g., in RPG, DDS, or COBOL) is being actively processed (e.g., creating, inserting, editing, deleting, and formatting) in a first system (e.g., in a Unicode editing system) that is targeted for ultimate processing by a second system (e.g., a non-Unicode environment such as DBCS).
There is a need to provide tools that enable a user, when processing a non-Unicode based document, in a Unicode computer operating environment, the ability to identify/manage problems in document structure and functions.
SUMMARY OF THE INVENTION
The present invention provides a method and system for processing a document on one system (i.e. Unicode) that is targeted to another system (i.e. non-Unicode) by active management to ensure that the formatting structure of the document such as field definitions is still intact after the eventual conversion to the it source/target system (i.e. non-Unicode). This is accomplished in an exemplary embodiment of the present invention by determining if a change to the document violates one of the field definitions associated with the document and providing an indication (e.g., visual indicators in the document, deny or edit blocks, etc.) when a field definition violation is determined.
In accordance with one aspect of the present invention, there is provided a method of processing (e.g., inserting, editing, deleting, formatting) a document having field definitions (e.g., an RPG document) targeted for a non-Unicode system (e.g.,iSeries EBCDIC DBCS) in a Unicode editor, the method comprising: determining if a change to the document (i.e., made in the Unicode editor) violates one of the field definitions associated with the document in the non-Unicode system; and providing an indication (e.g., setting a flag, visual indicators, denying the change, etc.) to the text editor when a field definition violation is determined.
In accordance with another aspect of the present invention, there is provided a system for processing a document having associated field definitions for a target system operating in a first encoding scheme in a text editor in a computing environment operating in a second encoding scheme, the system comprising: a mechanism configured to determine if a change to the document in the second encoding scheme violates one of the field definitions associated with the document in the first encoding scheme; and a mechanism configured to provide an indication to the text editor when a field definition violation is determined. In accordance with yet another aspect of the present invention, there is provided a computer-readable medium having computer-executable instructions for processing a document having associated field definitions targeted for a system operating in a first encoding scheme in a text editor operating in a second encoding scheme comprising: determining if a change to the document in the second encoding scheme violates one of the field definitions associated with the document in the first encoding scheme; and providing an indication to the text editor when a field definition violation is determined.
Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF DRAWINGS
The present invention will be described in conjunction with the drawings in which:
FIG. 1A is a block diagram representation of a text editing system that active processing of a document according to an embodiment of the present invention;
FIG. 1B is a block diagram representation illustrating an example document processing arrangement involving a Unicode operating environment and a non-Unicode operating environment;
FIG. 2 is a flow chart of a parser process according to an embodiment of the present invention;
FIG. 3 is a flow chart of the validation process, as part of the process of FIG. 2 , according to an embodiment of the present invention;
FIG. 4 is a flow chart of the insertion process, as part of the process of FIG. 2 , according to an embodiment of the present invention;
FIG. 5 is a flow chart of the deletion process, as part of the process of FIG. 2 , according to an embodiment of the present invention; and
FIGS. 6A and 6B are simplified block diagram representations of an exemplary computing environment suitable for implementing document processing according to the present invention.
DETAILED DESCRIPTION
By way of background, the need to support multiple languages in computer operating environments have traditionally been addressed by the development of language specific character sets and encoding schemes such as SBCS, DBCS or MBCS encoding formats as discussed above. For example, the SBCS encoding format can address most Roman based character sets, such as English. However, languages such as Japanese, Korean and Chinese require more than the 255 character positions that are available in SBCS which has resulted in the development of many unique DBCS and MBCS based encoding formats. The need for documents to contain a mix of encoding formats such as SBCS, DBCS, and MBCS has resulted in inter-operability issues when the documents are transferred between computer operating environments based upon different character encoding systems.
To address this issue, the Unicode character encoding format was developed to provide a standardized encoding format consisting of a two-byte representation across computer operating environments. This allows for 65,000 unique symbols to represent individually or in combination, the characters of most commonly used languages. However, there are a number of computer operating environments that use SBCS, DBCS or MBCS (non-Unicode) character encoding formats.
The problem addressed by the present invention arises when documents from a non-Unicode computer operating environment are maintained/processed (also termed active processing) with tools on a Unicode computer operating environment, which are not aware of the underlying formatting structure that must be maintained.
One programming language that utilizes field definitions is RPG. The field definitions provide a predefined formatting structure of the individual lines text. Each field represents a specific operation, data or command that is defined by set byte ranges (i.e. bytes 2 to 10, 11 to 16, 17 to 25). The field definitions that are in effect are determined by text in the lines themselves. Each line may contain different field definitions that must be maintained.
The conversion of a document supporting non-Unicode encoding to Unicode encoding can result in field violations. Field violations are most likely to occur in documents that contain mixed non-Unicode character encoding schemes, such as documents containing both SBCS and DBCS or MBCS. Some DBCS and MBCS character encoding formats require the addition of byte sequences such as Shift-Out (SO) and Shift-In (SI) identifiers and other escape-delimited byte sequences.
For example, the EBCDIC DBCS character encodings use SO and SI identifiers around DBCS character sequences. These sequences denote a transition to and from other character formats such as SBCS that may also be used within the same document. The sequences may add single or multiple bytes impacting the positioning of the text within the field definition. The resulting errors that may occur are not readily apparent to the user and can result in the improper execution of the commands or misrepresentation of the data contained within the document. In addition, during the editing of a document, the user may inadvertently impact the underlying structure when it is converted back to the non-Unicode encoding.
FIG. 1A illustrates a block diagram representation of a text editing system 100 that supports document processing according to an embodiment of the present invention. The functions of the text editing system 100 are defined by various modules discussed in detail below. Each module contains mechanisms that implement various functions for managing processes that are used during various document processing tasks.
The text editing system 100 includes a document management module 110 that provides high-level management (obtaining documents, screen displays, editing windows etc.) of a document being edited, using techniques known to those skilled in the art. The document management module 110 manages individual documents that are opened or newly-created within the text editing system 100 . The document management module 110 also controls various aspects of how the document is displayed and viewed and is accessible to other modules in the text editing system 100 .
The text editing system 100 further includes a text processing module 160 that handles the loading of documents into the document management module 110 and other text editing operations (such as validation, insertion and deletion). The text editing operations are controlled by respective mechanisms within the text processing module 160 . More specifically, validation operations are controlled by a validation mechanism 162 , and editing operations by an editing mechanism 168 which includes an insertion mechanism 164 and a deletion mechanism 166 . The validation and editing mechanisms ( 162 and 168 ) are accessed depending on the specific functions required and editor parameters in effect and will be discussed in more detail below.
The text processing module 160 interacts with a parser module 180 . When the document is initially loaded in the system 100 , the text processing module 160 calls the parser module 180 to perform a parse of the document. Subsequent changes to the text of the document can also trigger the parser module 180 to perform incremental parsing. In turn, the parser module 180 has full access to the text of the document, and may set parser information and display information (such as syntax coloring) in the document.
The text editing system 100 includes a base parser module 150 which implements a set of generic parser services (e.g., navigation, basic formatting, indentation) and provides an interface component (not shown) to the text editing system 100 . The base parser module 150 interacts with the parser module 180 , which addresses document specific requirements based upon the target languages such as RPG, DDS, COBOL, etc.
The text editing system 100 also includes an editor parameters module 170 that obtains or establishes various settings of the text edit system 100 by interaction with a user for example through a command line mechanism, and programmatically through an application program interface (API) for the use by components external to the text editing system 100 (such as parsers) using well known techniques.
The editor parameters module 170 includes a source encoding mechanism 172 for determining the source encoding of an originating document, which can be used by the mechanisms ( 162 and 168 ) of the text processing module 160 . The source encoding mechanism 172 can use a lookup table to determine a mapping of the Unicode text format to a source character encoding such as SBCS, DBCS or MBCS. By determining the source encoding, the addition of commands or sequences such as SO and SI identifiers, as previously discussed, can be accounted for in the text editing functions. The source encoding also provides for calculations of a text string's length in bytes, calculations of byte-sensitive boundaries of DBCS and MBCS characters and character sequences, and correlation between source byte positions and Unicode character positions in the text.
The editor parameters module 170 also includes a field definitions mechanism 174 for determining field definitions within an originating document, which can be used by the mechanisms ( 162 , 168 ) of the text processing module 160 . Determination of what field definitions are in effect for a particular line in an originating document helps to ensure the integrity of the definitions when operations are being performed by the mechanisms ( 162 , 168 ) within the text processing module 160 .
For example, in an RPG document, the sixth column or byte, designates the type of statement represented by that line, be it a Header, File Description, Input, Calculation, Output, etc., statement. The statement type in turn defines the field definitions that are required for that line. The determination of the field definitions assists in determining where field violations occur and can be unique to the target language of the document. The language specific document parser contained in parser module 180 , will affect how the field definitions are determined/defined for the document being edited and are directly related to the structural/formatting requirements of the language.
The parser module 180 analyzes the originating document, and marks structural elements in the document at various degrees of detail. Information collected by the parser module 180 is used by the document management module 110 to aid in displaying the document. The parser module 180 allows navigation between structural elements of the document and determines the definition of editing fields for a given text line being edited based on its type. In a programming language source document, each line is an element. An element class definition describes the type of data the element contains. An element may contain more than one element class. The element displayed below includes the code and comment classes. The style of an element determines the way an element will be displayed. The parser 180 sets a string of style characters that is equal in length to the text of the element. The system 100 draws each character of an element text with the attributes of the style character that is in the corresponding position in the element style string. The style of the element displayed below includes keyword, layout blank, punctuation, identifier, operator, quoted string, and comment style characters.
code class
comment class
Line of C code, element text
if (x == “test”)
/*test for x*/
Element style
kk_pi_oo_qqqqqqp —
cccccccccccccc
The parser module 180 includes a number of document parsers: an RPG parser 184 for handling RPG documents and parsers for other languages 186 for handling other types of documents such as C++ programming language source and the like. The various document parsers ( 184 , 186 ) in the parser module 180 are attached by a document-type association. For example, the RPG parser 184 is activated when an RPG document (*.RPG, *.OPMRPG, etc.) is loaded or created in the text editor 100 . The document parsers ( 184 , 186 ) provide an initial parse of the document and are used following any changes that are made to the document.
FIG. 1B illustrates an example arrangement of environments supporting active processing of a document 194 according to the present invention. In the arrangement of FIG. 1B , a document (e.g., an RPG formatted document) is being processed in the text editing system 100 functioning in a Unicode operating environment 190 . The target environment for the document 194 is, however, an operating language 196 residing in a non-Unicode operating environment 192 (e.g., EBCDIC DBCS).
Document Parser
FIG. 2 illustrates a flow chart of a parser process 200 according to an embodiment of the present invention. The parser process 200 , is implemented for example as part of the RPG parser 184 or other language specific parsers 186 .
The process 200 commences by determining if the parser ( 184 or 186 ) has been activated by the generation of a new document (YES at step 220 ) or the importing of an existing document (NO at step 220 ). If a RPG document is imported at 230 , the validation process 300 (refer to FIG. 3 ) is performed. Once the editing process has commenced on a newly created or imported document, editing functions are actively monitored to determine if a change in the document has occurred.
The parser process 200 determines at step 250 if a change (eg. insertion, deletion, edit, or re-format) will cause a violation in a field definition. If the change does not result in a field violation (NO at step 250 ), the change is allowed to occur 260 while maintaining the field boundaries/definitions by adding or deleting spaces as detailed subsequently in conjunction with FIGS. 4 and 5 . If a field violation would occur as a result of the change (YES at step 250 ), a violation flag can be set at step 270 . The violation flag is an indicator that initiates an appropriate function that is to occur next depending on a mode of operation of the text editing system 100 .
More specifically, the violation can be identified at step 272 to the user through a user interface of the text editing system 100 , allowing the user to see the impact of the change on the document as detailed in the validation process 300 . If the change is the result of an insertion, the insertion may be denied 274 (refer to FIG. 4 for details). Finally, if the change is the result of a deletion then the deletion may be denied at step 276 (refer to FIG. 5 for details).
As described above in conjunction with FIG. 2 , the present invention implements a series of processes: the validation process 300 (shown in FIG. 3 ), the insertion process 400 (shown in FIG. 4 ) and the deletion process 500 (shown in FIG. 5 ). These processes are implemented through the corresponding mechanisms ( 162 , 164 , 166 ) of the text processing module 160 in the text editing system 100 . Details of these processes ( 300 , 400 , and 500 ) will be described in conjunction with a practical example illustrated with various tables provided below.
Table 1 shows a representation of the conversion from text characters to Unicode, SBCS and DBCS formats and a byte representation that is used in the discussion of the examples.
TABLE 1
Unicode
SBCS
Roman
Non-Roman
Byte
Byte
DBCS Byte
DBCS with
Characters
Character
Format
Format
Format
SO/SI
a
a 1 a 2
a 1
—
—
b
b 1 b 2
b 1
—
—
c
c 1 c 2
c 1
—
—
D
D 1 D 2
—
D 1 D 2
>D 1 D 2 <
E
E 1 E 2
—
E 1 E 2
>E 1 E 2 <
F
F 1 F 2
—
F 1 F 2
>F 1 F 2 <
x
x 1 x 2
x 1
—
—
y
y 1 y 2
y 1
—
—
The non-Roman characters used in Japanese or Chinese is represented by upper case letters such as “D” in the following examples and consists of a two-byte sequence such as D 1 D 2 . If a transition to or from SBCS to DBCS characters occurs, the addition of escape-delimited byte sequences such as SO and SI identifiers is required for EDCDIC DBCS character encodings The SO and SI identifiers are shown by “>” and “<” in these examples and require a single byte each. The following examples use the DBCS character format; however, the same approach can be used to account for MBCS character formats that may use multi-byte escape sequences. All the characters in the Unicode encoding are represented by two bytes.
Validation
The validation process 300 , as shown in FIG. 3 , is performed to ensure that no field boundary divides the bytes of a DBCS or MBCS character, to ensure that no field boundary splits a DBCS or MBCS character sequence including its delimiting SO and SI or other multi-byte escape byte sequences, and to identify these violations (to a user for example). Identifying these errors and enabling them to be corrected can save time and effort in converting and debugging the document.
When the validation process 300 , is executed, the encoding (i.e., the type of encoding) of a source file (i.e., a document) is determined at step 310 by the source encoding mechanism 172 ; and the field definitions that are in effect for the document or particular line of text are determined at step 320 by the field definitions mechanism 174 in conjunction with the document parser 180 . The location of any SO and SI bytes (or identifiers), if applicable to the source encoding in effect, are determined at step 330 . The impact of the DBCS and MBCS byte sequences in the source encoding on field boundaries is determined at step 340 . If it is determined that there are field boundary violations (YES at step 350 ), then the violations are identified (e.g., to a user) through the document management module 110 , at step 360 . If there are no boundary violations (NO at step 350 ) then no identification is required at step 370 . The identification of field violation boundaries could result in the highlighting of the affected character or string, or a text message listing the exact position of the error, or both.
Validation Example
In Table 2 and Table 3, the editing in Unicode of a line of text in a document originating or targeted for a non-Unicode (mixed SBCS and EBCDIC DBCS) system is shown. One field is defined in this example from Byte 4 to 11; however, it is possible to have multiple field definitions in the same line. When the line is converted to Unicode, the corresponding field definition is defined by Unicode character positions 7 to 14.
TABLE 2
Non-Unicode
Displayed Text
a
b
c
D
E
x
Field
X
X
X
X
X
X
X
X
Definition
Byte Position
1
2
3
4
5
6
7
8
9
10
11
12
SBCS/DBCS
a 1
b 1
C 1
>
D 1
D 2
E 1
E 2
<
x 1
Byte
Representation
A representation of the line when converted to a Unicode environment is shown in Table 3.
TABLE 3
Unicode Displayed Text
a
b
c
D
E
x
Character Position
1
2
3
4
5
6
7
8
Field Definition
X
X
X
X
X
X
X
X
Byte Position
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Unicode Bytes
a 1
a 2
b 1
b 2
c 1
c 2
D 1
D 2
E 1
E 2
x 1
x 2
Representation
In this example, the field definitions remain intact during the conversion and there are no field violations.
In Table 4, a DBCS character sequence, bounded by the SO and SI character identifiers, crosses the start of the field definition at byte 3. The “●” indicates the byte position at which the field violation occurs.
TABLE 4
Non-Unicode Displayed Text
a
b
D
E
F
x
Field
•
X
X
X
X
X
X
X
X
Definition
Byte Position
1
2
3
4
5
6
7
8
9
10
11
12
SBCS/DBCS
a 1
b 1
>
D 1
D 2
E 1
E 2
F 1
F 2
<
x 1
Byte
Representation
When the text is converted to Unicode as in Table 5, byte positions 5 and 6 now contain the bytes of the non-Roman character D. Since the SO identifier is not present in the text converted to the Unicode encoding, it must be determined by the validation process 300 that the identifier sequence would cross the boundary when converted back to the non-Unicode or source encoding. The violation can be identified to a user by, for example, highlighting the character or the position of the character where the violation occurs.
TABLE 5
Unicode Displayed Text
a
b
D
E
F
x
Character Position
1
2
3
4
5
6
7
8
Field Definition
•
•
X
X
X
X
X
X
Byte Position
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Unicode Byte
a 1
a 2
b 1
b 2
D 1
D 2
E 1
E 2
F 1
F 2
x 1
x 2
Representation
By providing an immediate indication to a user that a field violation exists at Unicode character position 3, action can be taken to correct the problem early in the process, preventing encoding conversion errors, which will be more difficult to identify and correct.
Insertion
The insert process 400 , as shown in FIG. 4 , is performed to ensure that while the document is being edited, the user does not insert text that will cause a field violation in the originating source non-Unicode document. By not allowing field boundaries to be divided by the bytes of DBCS or MBCS characters or by SI or SO identifiers or other escape-delimited byte sequences, the integrity of the field definition is maintained. In general, if during an insertion a user does not cause a violation, the insertion is allowed to proceed, otherwise it is denied.
When the insertion process 400 is executed, for example by a user attempting to insert a character, the encoding of the source file is determined at step 310 by the source encoding mechanism 172 . The field definitions that are in effect for the particular line of text are identified at step 320 by the field definitions mechanism 174 in conjunction with the document parser 180 . The fields being defined in terms of source encoding bytes, the corresponding field for the current insertion point is determined inside the Unicode encoding processing environment for the current text line. The impact of the insertion on field boundaries is determined at step 430 and boundary violation results are assessed at step 440 .
If the insertion does not result in a violation of the boundary by the DBCS or MBCS byte sequence or SO or SI identifiers (NO at step 440 ), the insertion is allowed to occur at step 460 ; otherwise (YES at step 440 ) the insertion is denied at step 450 . When the insertion is allowed, the appropriate number of trailing spaces are deleted from the end of the field at step 470 , in order to maintain the integrity of this field, and that of the rest of the text on this line (including possibly other fields). The number of the deleted space characters depends on the effective increase in the source-encoding byte length resulting from the insertion.
INSERTION EXAMPLE
When the line of text in Table 2 is edited in the Unicode environment, if the user attempts to insert “a” at Unicode character position 5, the insertion does not appear to violate the defined field, as shown in the Unicode text of Table 6.
TABLE 6
Unicode Displayed Text
a
b
c
D
a
E
x
Character Position
1
2
3
4
5
6
7
8
Field Definition
X
X
X
X
X
X
X
X
Byte Position
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Unicode Byte
a 1
a 2
b 1
b 2
c 1
c 2
D 1
D 2
a 1
a 2
E 1
E 2
x 1
x 2
Representation
However, when the conversion to the source encoding is performed the insertion will cause a field overflow at byte position 12 as shown in Table 7. The addition of the SO and SI identifiers to the surrounding DBCS sequences cause the violation. By not allowing the insertion of the “a”, the field integrity is maintained.
TABLE 7
Non-Unicode
Displayed Text
a
b
c
D
a
E
x
Field
X
X
X
X
X
X
X
X
•
Definition
Byte
1
2
3
4
5
6
7
8
9
10
11
12
13
Position
SBCS/
a 1
b 1
c 1
>
D 1
D 2
<
a 1
>
E 1
E 2
<
x 1
DBCS
Byte
Repre-
sentation
However, if a DBCS character “F” was inserted instead as shown in Unicode text in Table 8, a violation does not occur.
TABLE 8
Unicode Displayed Text
a
b
c
D
E
F
x
Character Position
1
2
3
4
5
6
7
8
Field Definition
X
X
X
X
X
X
X
X
Byte Position
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Unicode Byte
a 1
a 2
b 1
b 2
c 1
c 2
D 1
D 2
E 1
E 2
F 1
F 2
x 1
x 2
Representation
Since the inclusion of the “F” (non-Roman character) does not cause the need of additional SO and SI identifiers, requiring more byte positions, the SO identifiers at byte 11 does not violate the field boundary and the field definition is maintained and the insertion is allowed to proceed as shown in Table 9. In order to maintain the field definitions, the additional trailing spaces are deleted thus ensuring that the position on “x” at byte 12 is not affected.
TABLE 9 Non-Unicode Displayed Text a b c D F E x Field X X X X X X X X Definition Byte 1 2 3 4 5 6 7 8 9 10 11 12 Position SBCS/ a 1 b 1 c 1 > D 1 D 2 F 1 F 2 E 1 E 2 < x 1 DBCS Byte Representation
Deletion
The deletion process 500 , as show in FIG. 5 , is performed to maintain the field definition of the current field by determining the effect on the source encoding when the selected characters are deleted. The field definitions are maintained by adjusting the field size to compensate for the deletion by padding the field with spaces.
When the deletion process 500 , is executed, the encoding of the source file is determined at step 310 by the source encoding mechanism 172 ; and the field definitions that are in effect for the document or particular line of text are determined at step 320 by the field definitions mechanism 174 in conjunction with the document parser 180 . The fields being defined in terms of source encoding bytes, the corresponding field for the current deletion point is determined inside the Unicode encoding processing environment for the current text line.
If a violation would occur, the deletion is denied at step 570 . Otherwise, the character is deleted at step 550 , and the necessary padding is performed at step 560 . The padding step 560 involves adding an appropriate number of trailing spaces to the end of the field, in order to maintain the integrity of this field, and that of the rest of the text on this line (including possibly other fields). The number of the added space characters depends on the effective decrease in the source-encoding byte length resulting from the deletion.
Deletion Example
In the following example, the user wishes to remove the non-Roman character ‘E’ starting at Unicode character position 5 as shown in Table 10 which corresponds to byte position 7 in the non-Unicode text of Table 11.
TABLE 10
Unicode Displayed Text
a
b
c
D
E
x
Character Position
1
2
3
4
5
6
7
8
Field Definition
X
X
X
X
X
X
X
X
Byte Position
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Unicode Byte
a 1
a 2
b 1
b 2
c 1
c 2
D 1
D 2
E 1
E 2
x 1
x 2
Representation
TABLE 11
Non-Unicode
Displayed Text
a
b
c
D
E
x
Field
X
X
X
X
X
X
X
X
Definition
Byte Position
1
2
3
4
5
6
7
8
9
10
11
12
SBCS/DBCS
a 1
b 1
c 1
>
D 1
D 2
E 1
E 2
<
x 1
Byte
Representation
The result of the character deletion is shown in the Unicode text in Table 12. Note that the character ‘x’ now falls within the field definition at character position 7.
TABLE 12
Unicode Displayed Text
a
b
c
D
x
y
Character Position
1
2
3
4
5
6
7
8
Field Definition
X
X
X
X
X
X
X
X
Byte Position
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Unicode Byte
a 1
a 2
b 1
b 2
c 1
c 2
D 1
D 2
x 1
x 2
y 1
y 2
Representation
Moreover, when the text is converted to the base encoding, the characters ‘x’ and ‘y’ will fall within the field definition as shown in Table 13.
TABLE 13
Non-Unicode
Displayed Text
a
b
c
D
x
y
Field Definition
X
X
X
X
X
X
X
X
Byte Position
1
2
3
4
5
6
7
8
9
10
11
SBCS/DBCS Byte
a 1
b 1
c 1
>
D 1
D 1
<
x 1
y 1
Representation
In order to maintain field integrity, two additional spaces are added to maintain the position of the characters that were originally outside of the field definition as shown in Table 14 and Table 15.
TABLE 14
Unicode Displayed Text
a
b
c
D
x 1
Character Position
1
2
3
4
5
6
7
8
9
Field Definition
X
X
X
X
X
X
X
X
X
X
Byte Position
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Unicode Byte
a 1
a 2
b 1
b 2
c 1
c 2
D 1
D 2
x 1
x 2
Representation
TABLE 15
Non-Unicode
Displayed Text
a
b
c
D
x
Field
X
X
X
X
X
X
X
X
Definition
Byte Position
1
2
3
4
5
6
7
8
9
10
11
12
SBCS/DBCS
a 1
b 1
c 1
>
D 1
D 2
<
x 1
Byte
Representation
In summary, according to an exemplary embodiment of the present invention, by combining validation, insertion, and deletion mechanisms ( 162 , 164 , 166 ), in an process that actively monitors the functions of the text editing system 100 , a user can ensure that the structure and formatting of a text document will be maintained when it is converted back to the source SBCS, DBCS and MBCS encoding.
FIG. 6A is a block diagram representation of a computing environment 600 in which the various embodiments of the present invention operate. The computing environment 600 includes a computer system 610 operationally coupled to a networked computer 612 through suitable network connections 614 and 616 and a network 618 . The network 618 can be any conventional network such as a local area network, wide area network, intranets, the Internet, and the like, or a convenient combination thereof. The network 618 provides a mechanism for transporting data, such as documents/data/instructions, to the computer system 610 . It will be appreciated that in alternative embodiments, the computer system 610 may not be connected to the network and documents/data/instructions will be provided directly to a computer 620 through an input device (e.g., keyboard, mouse) 622 or through a permanent or removable computer readable medium device 624 (e.g., hard disk, floppy disc, CD-ROM). Further, aspects of the present invention can be distributed amongst various networked computers interacting with the computer system 600 through the network 618 (and possibly a combination of networks).
The computer system 610 includes the computer 620 that communicates with various output devices such as a display terminal 626 and a printer 628 , with the network 518 , and with various input devices 622 and media reading devices 624 as discussed above. Other devices can include various computer peripheral devices (not shown) such as a scanner, tablets, and the like.
FIG. 6B illustrates a block diagram representation of the computer 620 shown in FIG. 6A . The computer 620 includes a bus 650 that operationally interconnects various subsystems or components of the computer 620 , such as a central processing unit (CPU) 652 , a memory 654 , a network interface 656 , and an input/output interface 658 .
The CPU 652 can be a commercially available CPU or a customized CPU suitable for operations described herein. Other variations of CPU 652 can include a plurality of CPUs interconnected to coordinate various operational functions. The input/output interfaces 658 to enable communication between various subsystems of the computer 620 and various input/output devices shown in FIG. 6A . The input/output interface 658 includes a video card for operational interfacing with the display terminal 626 , and preferably a disk drive unit or CD/DVD-ROM drive unit for reading suitable removable computer-readable medium, such as a floppy disk, or a CD. The removable medium provides programming instructions for subsequent execution by the CPU 652 to configure and enable the computer 620 to achieve the functions of the present invention.
The network interface 656 , in combination with a communication suite 660 , enables suitable communication between the computer 620 and other computers operationally connected through the network 618 as shown in FIG. 6A . Examples of conventional network interfaces 656 include an Ethernet card, a token ring card, a modem and the like. Optionally, the network interface 656 may also enable retrieval of transmitted programming instructions or data to configure and enable the computer 620 to achieve the functions of the present invention. Further, aspects of the present invention can be enabled in various computer systems operationally networked to form a distributed computing environment to achieve the functions of the present invention.
The memory 654 includes both volatile and persistent memory for storage of components 662 (including programmed instructions 664 and data structures 670 such as databases and lookup tables) that may be required by the embodiments of the present invention. An operating system 668 co-operates with the CPU 652 to enable various operational interfacing with various subsystems of the computer 620 , and for providing various functionality, such as multitasking and the like. | A document processing system and method for actively processing a document targeted for one system on another system. The method of processing a document having associated field definitions targeted for a system operating in a first encoding scheme in a text editor operating in a second encoding scheme includes determining if a change to the document in the second encoding scheme violates one of the field definitions associated with the document and providing an indication to the text editor when a field definition violation is determined. The processing functions include creating, inserting, editing, deleting and formatting. The document processing system can be used when editing RPG documents in a Unicode editor for ultimate processing by a non-Unicode system such as EBCDIC DBCS. The indications can include setting a flag, which can be used by the text editor to drive visual indicators of violations, deny changes and the like. | 69,856 |
This application is a continuation of Ser. No. 08/318,221 filed Oct. 5, 1994, now abandoned, which is a continuation of Ser. No. 08/184,905 filed Jan. 21, 1994, now abandoned, which is a continuation of Ser. No. 08/063,247 filed May 18, 1993, now abandoned, which is a divisional of Ser. No. 07/471,976 filed Jan. 29, 1990, now U.S. Pat. No. 5,292,655.
TECHNICAL FIELD OF THE INVENTION
The field of the invention is in biology and more specifically in the subspecialty of cell biology.
BACKGROUND OF THE INVENTION
The serum-free culture of normal human epidermal keratinocytes without the use of companion-cells, cell feeder layer or organotypic substrate, e.g. collagen or gelatin, is disclosed in this invention. Traditionally, tissue culture of normal epithelial cells has been attempted in a variety of commercially available media designed for the growth of less fastidious types of cells, i.e., malignant cells transformed in vitro from cell lines derived from human or nonhuman tissues, cell lines developed from human or nonhuman tumors, or cell lines developed from human or nonhuman embryonic mesenchymal cell types. In contrast, the culture of normal human epithelial stem cells has presented many difficulties not the least of which is the inexorable tendency for these cells to undergo uncontrolled, irreversible, terminal differentiation with the consequent loss of cell division capacity. A significant development which permitted the growth of human epidermal cells in culture was tile formulation of a selective basal nutrient medium and its supplementation with specified growth factors and hormones (Tsao, M. C., et al., J. Cellular Physiol. 110:219-229 (1982)). This selective medium was designated MCDB 152. Further refinements of this medium lead to the formulation of MCDB 153 (Boyce, S. T. and Ham, R. G., J. Invest. Dermatol. 81:33-40 (1983). The use of these media permitted a more accurate characterization of the necessary growth factors, hormones and Ca 2+ requirements for retention of high cloning efficiency necessary to maintain proper genetic programming for continued subculture of pluripotent basal epidermal stem cells (Wille, J. J., et al., J. Cellular Physiol. 121:31-44 (1984)).
The actual role of serum in a cell culture medium as a complex mixture of both growth factors and differentiation-inducing factors was resolved by careful clonal growth, cell division kinetics, and flow cytofluorography (Pittelkow, M. R., et al., J. Invest. Dermatol. 86:410-417 11986)). These findings indicated that serum, known to contain fibroblastic cell growth factors, e.g., platelet-derived growth factor, was an inhibitor of basal epidermal cell growth. Further, the differentiation-inducing factors in serum could be equated with serum's content of β-transforming growth factor, (β-TGF), (Shipley, S. D., et al., Cancer Res. 46:2068-2071 (1986)). Recently, the inventor and colleagues reported that normal human keratinocytes actually produce their own growth factors. That is, proliferating basal cells are stimulated to secrete α-transforming growth factor (α-TGF) in response to the presence of added epidermal growth factor (EGF) and decrease production of α-TGF at high cell densities near confluence. Under the latter condition, the arrested cells secrete an inactive form of β-TGF (Coffen, R. J., et al., Nature 328:817-820 (1987)). These considerations recently led the inventor to the idea that the natural mechanism of growth stimulation and its regulation in intact epidermis involved coordinated secretions of α- and β-TGF's, and that the provision of such factors would eliminate the need for any organic substrate as well. Further experimentation to verify this surmise resulted in the findings in the present invention.
Previously, a patent (Green, H. and Kehinde, O., U.S. Pat. No. 4,304,866, 1981) was obtained for an in vitro method for the formation of epithelial sheets from cultured keratinocytes. This method uses a serum-containing medium and a feeder layer of murine (mouse) fibroblast cells to accomplish cell growth and differentiation. This procedure has serious limitations for large scale production of genetically-defined (autologous) human skin substitute. For example, the use of serum inextricably confounds the culture of purely basal cells with the dynamics of serum-induced differentiation. The net result is that subcultivation of such cultures yields low (<5%) clonal efficiencies preventing step-wise large scale build up of uncommitted pluripotent basal cells as a prelude to their conversion into usable sheets of transplantable, histologically-complete, human epidermis. Moreover, the process of Green, H. and Kehinde, O. (U.S. Pat. No. 4,304,866, 1981) does not describe a histologically-complete epidermis. Rather, the procedures therein can only form an epidermis lacking a stratum corneum, this being necessary for maximizing the utility of the tissue, and, thus, this limits the product uses. In a more recent methodology, a complete epidermis has been achieved, but only in the presence of a complete skin starter sample and serum-containing media that are combined with an organotypic substratum containing growth factors produced by companion cells (E. Bell, U.S. Pat. No. 4,485,096, 1984; and E. Bell & L. Dubertret, U.S. Pat. No. 4,604,346, 1986). Although it is conceivable that these latter processes may be used in the absence of serum, the continued use of any organotypic substrate as well as feeder or companion cell types, e.g. fibroblasts, seriously limits, in an immunologically safe manner as well as an economic manner, their large-scale use, e.g. burn patients (Nanchahal, J., et al., Lancet II(8656):191-193, (1989)). In order to remedy these deficiencies the inventor has dispensed with serum-containing media, eliminated any substratum support, dispensed with the requirement for innumerable skin starter samples, and designed a new basal nutrient medium capable of supporting the growth and development of a complete epidermis. Moreover, the identification of essential process steps leading to a functional epidermis has been discovered and can be monitored with specific monoclonal antibodies. In retrospect, the culturing of epidermal keratinocytes in medium containing undefined serum and/or feeder cell factors and/or organotypic substrates, and millimolar concentrations of Ca 2+ were not designed for the unlimited proliferation of undifferentiated basal cells. Such cultures can spontaneously undergo maturation and uncontrolled differentiation. The result was that an incomplete epidermis was produced. By contrast, the design of the serum-free culture process described in this invention produces a complete epidermis i.e. an epidermis which is formed of all six major identifiable layers of a complete human epidermis by an orderly sequence at will, from a defined starting point in the culture process.
SUMMARY OF THE INVENTION
There is disclosed the design and formulation of the novel HECK-109 media which have been differently supplemented to provide for the serial achievement of the three-step cellular differentiation process of pluripotent basal cell keratinocytes to a fully differentiated human skin in vitro: i) HECK-109, the basal medium for cell starting; ii) HECK-109 fully-supplemented medium (hereinafter referred to as HECK-109FS) for control over cellular growth; iii) HECK-109-differentiation medium (hereinafter referred to HECK-109DM) for the induction of differentiation and formation of a Malpighian layer; and iv) HECK-109-cornification medium (hereinafter referred to HECK-109CM) designed for the induction of cellular differentiation of a stratum lucidum, stratum corneum, and stratum disjunction in a pre-existing reformed epidermis produced by HECK-109DM. The entire system involves the matter of the sequential rendering of the culture process steps and the method of sequential control in the in vitro construction of a histologically-complete living skin substitute in a totally serum-free medium, feeder layer-free, and matrix-free (collagen or other organotypic matrix) process.
This disclosure includes: I. a nutrient basal medium designated HECK-109. The critical component concentrations incorporated into this medium design are about: i) N-(2-OH-ehtyl-)piperazine-N'-(2-ethanesulfonic acid) (hereinafter referred to as HEPES) at 14-22 mM; ii) NaCl at 90-140 mM; iii) low Ca 2+ level at 0.03-0.3 mM; and iv) six key amino acids of Stock 1 of HECK-109 (SEE: TABLE 1) set at about the following concentrations, Histidine=1.0-2.5×10 -4 M; Isoleucine=0.5-5.0×10 -4 M; Methionine=1.0-5.0×10 -4 M; Phenylalanine=1.0-5.0×10 -4 M; Tryptophan=0.5-5.0×10 -4 M; and Tyrosine=1.0-5.0×10 -4 M. Taken together, HEPES, NaCl, and the six key amino acids are critically superior to any previous media or similar design, in toxicity, osmolarity, and support of clonal growth of basal epidermal cells; II. a growth medium for undifferentiated basal keratinocytes based on HECK-109 basal medium and herein designated HECK-109FS. This medium consists of basal nutrient medium HECK-109 supplemented at about the following levels: Ca 2+ =0.03-0.30 mM; hydrocortisone=1.0-5.0×10 -7 M; phosphoethanolamine=0.5-2.0×10 -4 N; ethanolamine=0.5-2.0×10 -4 M; epidermal growth factor (EGF)=1-25 ng/ml; insulin-like growth factor-1 (IGF-1)=0.3-30 ng/ml; and soy bean trypsin inhibitor (SOTI;=0.1-1.0% w/v). This medium is selective for the growth of normal human epidermal keratinocytes and is essential for Phase I of the culture growth in that it supports the formation of a hole-free monolayer of undifferentiated keratinocytes while suppressing growth-arrest and any significant decline in clonogenic potential. These properties are unlike any previous media used to support proliferation of basal keratinocytes. The key features of HECK-109FS which make it different and superior to allother keratinocyte growth media are the use of IGF-1 and EGF as the only two protein growth factors used in conjunction with low Ca 2+ (0.03-0.30 mM); III. a cytodifferentiating growth medium based on basal HECK-109 medium and herein designated HECK-109DM. As detailed in the disclosure, Example 4, the induction of synchronous growth arrest, commitment to terminal keratinocyte differentiation, and formation of a supra-basal cell layer superimposed on top of a proliferation-competent basal cell layer is achieved by replacement of HECK-109FS with HECK-109DM. The latter medium is composed of HECK-109 basal medium supplemented at about the following levels: Ca 2+ =0.7-3.0 mM; hydrocortisone=1-10×10 -7 M; phosphoethanolamine=0.5-2.0×10 -4 M; ethanolamine=0.5-2.0×10 -4 M; EGF=1-5 ng/ml; IGF-1=0.3-30.0 ng/ml; and β-transforming growth factor (β-TGF)=3-30 ng/ml. Addition of β-TGF is a key required to arrest basal keratinocytes through a pathway that prepares the monolayer for induction of stratification, a step under the joint control of EGF (1-5 ng/ml), β-TGF (3-30 ng/ml), and Ca 2+ (0.7-3.0 mM). HECK-109DM must be replaced by HECK-109CM (Cornification-inducing Medium) to achieve the final steps in the induction of a full-thickness, histologically-complete epidermis; IV. a differentiation and cornification medium based on basal HECK-109 medium and herein designated HECK-109CM. This medium is designed to induce the competent formation of a stratum corneum, which also leads to the appearance of a stratum lucidum and stratum disjunction. HECK-109CM is based on HECK-109 basal medium and has about the following levels of critical components which achieve this step (in addition to HECK-109 basal medium): linoleic acid=1-15 μg/ml; hydrocortisone=1.0-10.0×10 -7 M; phosphoethanolamine=0.5-2.0×10 -4 M; ethanolamine=0.5-2.0×10 -4 M; and Ca 2+ =0.7-3.0 mM; V. a method, including design and formulation of a cell competency solution (herein designated CCS), whereby clonally competent basal keratinocytes are isolated from human skin samples by the procedures outlined in Example 1. The essence of these steps is the recovery of a unique subpopulation of basal cells which differ from basal cells tightly associated with the dermis. Separation versus tight association is defined as those cells (the unique disassociated subpopulation) which are recovered from treatment of a human skin biopsy with 0.1-0.2 percent trypsin (w/v) dissolved in CCS. CCS is designed to permit the initial isolation of a subpopulation of clonally competent basal keratinocytes that retain a high clonality. This is due to the low toxicity of this medium and improved osmolality which differ from all other isolation solutions for such cells. The approximate composition of (:CS is as follows: glucose=10 mM; KCl=3 mM; NaCl=90-140 mM; Na 2 HPO 4 . 7H 2 O=1 mM; phenol red=0.0033 mM; HEPES=16-22 mM; 100 Units per ml both of penicillin and streptomycin and SOTI=0.1-1.0 percent (w/v). The isolated subpopulation of competent basal cells are then seeded into HECK-109FS at 5×10 4 cells/cm 2 and are clonally amplified to the density of 2×10 4 to 2×10 5 cells/cm 2 prior to their serial passage into secondary culture, and the clonal growth of said cells; and VI. a method wherein the requirements for the preparation and sequential differentiation of a secondary proliferating monolayer of undifferentiated or differentiated keratinocytes are outlined (referred to as Phases I, II, and III). Said procedures include the seeding of clonally competent keratinocytes into HECK-109FS at an initial cell density of about 5×10 2 to 3×10 3 cells/cm 2 and their growth to a density of about 2-4×10 5 cell/cm 2 prior to the induction of differentiation (Phase I) and sequential formation of a histologically-complete stratified epithelium by the controlled progressive and sequential culture of the cells in HECK-109DM (Phase II), and HECK-109CM (Phase III) wherein the final in vitro skin product contains all layers of a histologically complete epidermis.
The above description discloses a process that is premised upon the realization that a viable, and completely reformed human epidermis with a stratum corneum can be entirely reformed in culture by following an orderly sequence of steps hitherto unknown whereby these steps are absent serum, feeder cells or organotypic substrates of any type. Phase I is the culturing of primary normal human keratinocytes in a newly designed serum-free medium (Medium HECK-109). Although the usual procedure for obtaining keratinocytes involves foreskins, adult skin specimens from virtually any body site and of at least 1 to 2 cm 2 (such as a punch biopsy) provides a sufficient number of input cells to start a primary culture. Phase I is capable of amplifying the initial input of cells of the epidermis by a factor of 100,000 by serial subcultivation procedures (secondary cultures), requires less than two weeks, and provides enough basal cells to eventually form about 2 to 3 square meters of histologically complete and viable epidermis. Once secondary cultures of basal cells have been amplified in Phase I to the desired extent, the proliferating cultures are stimulated to reach confluence and form a hole-free sheet in the presence of a medium designed to ensure retention of undiminished clonal growth. This supplementation step is crucial. It is achieved by replacing the basal HECK-109 serum-free culture medium with HECK-109 medium enriched in specific amino acids outlined above and linoleic acid. In this latter medium, the basal cells within the monolayer continue to proliferate resulting in the formation of a crowded monolayer, with continued clonal growth capacity until used in Phase II in the process.
Phase II in the cell culture process is the induction of identifiable cell strata with the formation of a nondividing suprabasal cell layer, and continued proliferation of the underlying basal cells. These events are simultaneously induced by replacement of the second-step HECK-109 enrichment medium with the basal HECK-109 serum-free medium containing β-TGF (3 to 30 ng per ml), and Ca 2+ (0.7 to 3.0 mM). This medium additionally lacks EGF and IGF-1. Within a few days, the proliferating cell monolayer converts into a stratified epidermis, which then progressively thickens to form a multilayered living sheet of epidermis. This process continues for about a week in culture and completes Phase II of in vitro formation of a human epidermis.
At this stage, the epidermis consists of three histologically recognizable and antibody-identifiable cell layers, a bottom-most basal cell layer (stratum germinativum), a spinous cell layer (stratum spinosum) above it, and a top-most granular cell layer (stratum granulosum), but no formation of a cornified stratum (stratum corneum), or bordering layers, e.g. stratum lucidum and stratum disjunction. This development requires a third phase of culture. The second phase culture, characterized by an incomplete epidermis, will persist in culture for an extended period (>30 days). It will, however, lose the capacity to convert to a complete epidermis. This is prevented by initiation of Phase III of culture. The second phase medium is replaced with a first-phase serum-free medium that lacks all added protein growth factors but has elevated Ca 2+ (0.7-3.0 mM) and linoleic acid (1-15 μg/ml) in the medium.
Unlike the characterization of all existing methods and processes the construction of a completely reformed human epidermis in the above manner is vastly superior to any method employing serum-containing media and/or feeder layer support and/or organotypic matrices because it is faster, reproducible and provides a uniform composition to the finished product from an autologous source. It also affords the possibility of intervening at any of the crucial steps in the process in ways that might augment the cellular content of one of the living versus nonliving cell layers. Finally, the ease of amplifying the initial input through rapid serial cell culture makes this the choice method for instituting autografts within the framework of the time constraints operative during therapeutically-assisted recovery of severe burn patients besides being a long term solution in this and other wound healing problems.
DETAILED DESCRIPTION OF THE INVENTION
EXAMPLE 1
Primary and Secondary Culture of Normal Human Epidermal Keratinocytes in HECK-109 Serum-Free Medium.
Isolation of Basal Cells and Primary Cultures
Through extensive experimentation, I have developed HECK-109, a new serum-free medium, and developed methods detailed below for the successful propagation of normal human basal epidermal keratinocytes from either newborn or adult skin. Primary cultures of normal human basal epidermal keratinocytes are started by subjecting full-thickness skin samples to enzymatic digestion. Skin obtained from biopsies or autopsies is first cleaned of adhering subdermal fat and the dermis is reduced to less than 3 mm in thickness. The skin sample is then typically cut into 8 to 12 small pieces (usually 0.5 cm 2 ). These pieces are floated on top of a sterile Cell Competency Solution CCS; CCS as follows: glucose, 10 mM; KCl, 3 mM; NaCl, 90-140 mM; Na 2 HPO 4 .7H 2 O, 1 mM; phenol red, 3.3 μM; and HEPES at 14-22 mM, (SEE: Shipley, G. D. and Ham, R. G., In Vitro 17:656-670 (1981)), additionally containing 0.10-0.20 percent, trypsin (w/v), and antibiotics, 100 units/ml of both penicillin and streptomycin. After 14 to 16 hours of digestion at 4° C. the dermis is separated from the epidermis by a split-dermis technique. This is accomplished by inverting the skin sample, i.e., by placing the cornified layer side of the epidermis onto a clean sterile polystyrene surface, as accomplished by existing typical techniques. The epidermis spontaneously detaches, and the dermis is removed with sterile forceps. I have shown that trypsin digestion cleaves the skin along a fracture line which separates some of the basal cells with the dermis, but frees other basal cells lying between the dermis and the fracture line just above the basal cell layer.
The trypsin-treated epidermis, so split from the dermis, is enriched for a subpopulation of loosely-associated, clonally competent basal cells. In a series of experiments, I discovered that these loosely-associated basal cells are larger than the basal cells that remain associated with the dermis. Moreover, these larger basal cells are separable by cell sorting procedures using a florescence-activated cell sorting device. They also have a greater colony-forming ability than the dermis-associated basal cells, as demonstrated by clonal growth experiments.
The loosely-associated basal cells are collected in ice-cold (0° to 40° C.)-CCS containing 0.1-1.0 percent w/v SOTI solution as outlined above, and the cell suspension filtered on ice through a 100 micrometer sized Nylon mesh by sterile procedures. Filtration removes cell aggregates and ensures preparation of a single cell suspension. The cells are pelleted by low speed centrifugation (800×grav, 5 minutes) at 4° C. The above solution is aspirated off and the remaining cells are resuspended by gentle pipetting in CCS, and washed once with ice-cold, serum-free basal nutrient medium (here designated HECK-109; see Example 2 for detailed composition of this medium). The centrifugation step is repeated as above, and the resulting cell pellet is resuspended in 1 to 2 ml of fresh HECK-109 medium. Cell counts are obtained by standard cell chamber counting methods. Primary cultures are initiated into HECK-109 medium supplemented with 0.1 (0.05-0.20) mM ethanolamine; 0.1 (0.05-0.20) mM phosphoethanolamine; 0.5 (0.1-1.0) μM hydrocortisone; 0.2 percent (0.1-1.0) of SOTI, w/v. Antibiotics which are added at this time can be removed 2 to 3 days later when the proliferating cell cultures are refed fresh complete medium. The complete growth medium (HECK-109FS) is further supplemented with 10 ng/ml EGF (1-25 ng/ml), and 5 μg/ml IGF-1 (0.3-30 ng/ml). The latter two protein growth factors are added aseptically to the medium. Other medium supplements and media with the above supplements are sterilized through a commercially available membrane filter. The initial seeding density for initiating the primary culture is 5×10 4 basal cells per 75 cm 2 tissue culture flask. Generally, two such flasks are routinely set up from an initial yield of 1 to 2×10 6 cells isolated from a 1 to 2 cm 2 piece of skin.
Secondary Culture Procedure
Secondary cultures initiated from either primary cultures or early passage secondary cultures are passaged by enzymatic dissociation of cells. This serial passage technique is not standard. It involves the use of ice-cold 0.02 (0.02-0.20) percent trypsin (w/v) and 0.1 (0.08-0.12) percent ethylenediaminetetraacetic acid (EDTA; w/v) dissolved in CCS to remove the cells from their plastic substrate. The cells are collected in ice-cold 0.2 (0.1-1.0) percent SOTI (w/v) in CCS as detailed above for initiating primary cultures. Typically, secondary cultures are seeded at an initial cell density at a 1000 cells per cm 2 , but lower seeding densities are possible.
The procedures for calculating colony forming efficiency (CFE) of the basal cells recovered from the epidermis and used to initiate a primary culture is to set up duplicate primary cultures at 5000 cells per cm 2 and described above, and then to count the number of cells which attach and which later form a colony of at least 8 or more cells three days after seeding the primary culture. By this method, the percent attachment of epidermal cells is 50 to 60 percent of the input cells. The colony forming efficiency ranges between 0.1 to 0.5 percent of the input cells as measured by ocular micrometer grid square counts on living cultures.
EXAMPLE 2
Preparation of HECK-109 Basal Nutrient Medium
Some of the novel methods and materials provided by the invention relate to the preparation of a new basal nutrient medium suitable for the large scale amplification of both primary and secondary cultures of normal human keratinocytes, and for conversion of proliferating normal human keratinocyte monolayer cultures to a stratified squamous epithelium applicable to a transplantable skin equivalent. More particularly, Example 2 is directed to the materials and procedures for preparation of a basal nutrient medium (Human Epidermal Cell Keratinocyte, HECK-109), and evidence for its superiority in stimulating epidermal growth by design of the osmolarity, toxicity, and pH-buffering properties of the standard basal medium formulation.
Table I, below, details the concentration of components in basal medium, HECK-109. All biochemicals and hormones are from Sigma Chemical Company (St. Louis, Mo., U.S.A.), and all inorganic chemicals are from Fisher Scientific (Pittsburgh, Pa., U.S.A.). All trace elements in Stock T are from Aesor (Johnson Matthey, Inc., Seabrook, N.H., U.S.A., Purotronic Grade). EGF may be prepared according to the procedure of Savage, R. C. and Cohen, S. (J. Biol. Chem. 247:7609-7611 (1972)), or purchased from Collaborative Research, Inc., Waltham, Mass.
One liter of HECK-109 is prepared in a separate stock solution fashion as described in Table I with respect to Stocks 2 through 10. Medium HECK-109 differs from all other media in the prior apt by its Stock 1 amino acids, its concentration of NaCl (113 mM; Range 90-140) and of HEPES (20 mM; Range 14-22). The design of the level of amino acids must include the following 6 amino acids: Isoleucine=0.5-5.0×10 -4 M; Histidine=0.5-2.5×10 -4 M; Methionine=1.0-5.0×10 -4 M; Phenylalanine=1.0-5.0×10 -4 M; Tryptophan=0.5-5.0×10 -4 M; Tyrosine=1.0-5.0×10 -4 M.
TABLE I______________________________________Composition of Basal Nutrient Medium HECK-109 Concentration in final mediumStock Component mg/l mol/l*______________________________________1 Arginine.HCl 421.4 2.00 × 10.sup.-3 Histidine.HCl.H.sub.2 O 36.1 1.70 × 10.sup.-4 Isoleucine allo-free 33.0 2.50 × 10.sup.-4 Leucine 132.0 1.00 × 10.sup.-3 Lysine.HCl 36.6 2.00 × 10.sup.-4 Methionine 45.0 3.00 × 10.sup.-4 Phenylalanine 50.0 3.00 × 10.sup.-4 Threonine 23.8 2.00 × 10.sup.-4 Tryptophan 40.8 2.00 × 10.sup.-4 Tyrosine 54.0 3.00 × 10.sup.-4 Valine 70.2 6.00 × 10.sup.-4 Choline 20.8 2.00 × 10.sup.-4 Serine 126.1 1.20 × 10.sup.-32 Biotin 0.0146 6.00 × 10.sup.-8 Calcium Pantothenate 0.285 1.00 × 10.sup.-6 Niacinamide 0.03363 3.00 × 10.sup.-7 Pyridoxal.HCl 0.06171 3.00 × 10.sup.-7 Thiamine.HCl 0.3373 1.00 × 10.sup.-6 Potassium chloride 111.83 1.50 × 10.sup.-33 Folic acid 0.79 1.80 × 10.sup.-6 Na.sub.2 HPO.sub.4.7H.sub.2 O 536.2 2.00 × 10.sup.-34a Calcium chloride.2H.sub.2 O 14.7 1.00 × 10.sup.-44b Magnesium chloride.6H.sub.2 O 122.0 6.00 × 10.sup.-44c Ferrous sulfate.7H.sub.2 O 1.30 5.00 × 10.sup.-65 Phenol red 1.242 3.30 × 10.sup.-66a Glutamine 877.2 6.00 × 10.sup.-36b Sodium pyruvate 55.0 5.00 × 10.sup.-46c Riboflavin 0.03764 1.00 × 10.sup.-77 Cysteine.HCl 37.6 2.40 × 10.sup.-48 Asparagine 13.2 1.00 × 10.sup.-4 Proline 34.53 3.00 × 10.sup.-4 Putrescine 0.1611 1.00 × 10.sup.-6 Vitamin B.sub.12 0.407 3.00 × 10.sup.-79 Alanine 8.91 1.00 × 10.sup.-4 Aspartic acid 3.99 3.00 × 10.sup.-5 Glutamic acid 14.71 1.00 × 10.sup.-4 Glycine 7.51 1.00 × 10.sup.-410 Adenine 12.16 9.00 × 10.sup.-5 Inositol 18.02 1.00 × 10.sup.-4 Lipoic acid 0.2063 1.00 × 10.sup.-6 Thymidine 0.7266 3.00 × 10.sup.-6Traceelement Copper sulfate.5H.sub.2 O 0.00025 1.00 × 10.sup.-9T Selenic acid 0.00387 3.00 × 10.sup.-8 Magnesium sulfate.5H.sub.2 O 0.00024 1.00 × 10.sup.-9 Sodium silicate.9H.sub.2 O 0.1421 5.00 × 10.sup.-7 Ammonium molybdate.4H.sub.2 O 0.00124 1.00 × 10.sup.-9 Ammonium vanadate 0.00059 5.00 × 10.sup.-9 Nickel chloride.6H.sub.2 O 0.00012 5.00 × 10.sup.-10 Stannous chloride.2H.sub.2 O 0.000113 5.00 × 10.sup.-10 Zinc chloride.7H.sub.2 O 0.1438 5.00 × 10.sup.-7Solids Glucose 1081.0 6.00 × 10.sup.-3S Sodium acetate.3H.sub.2 O 500.0 3.70 × 10.sup.-3 Sodium bicarbonate 1176.0 1.40 × 10.sup.-2 Sodium chloride 6600.0 1.13 × 10.sup.-2 HEPES 4700.0 2.00 × 10.sup.-2______________________________________ *All above components come together to a final volume of 1 liter of distilled and 0.22 μmfiltered water.
The indicated concentrations of these 6 amino acids have been shown by the inventor to be necessary for sustained basal cell proliferation. By further experimentation, the inventor showed that superior growth occurs when the osmolarity of the basal nutrient medium is (275-325) milliosmoles (mOsM). Finally, through an extensive series of clonal growth experiments in which the osmolarity was held constant at 300 mOsM and the concentration of HEPES varied between 14 to 28 mM it was discovered that the design of HECK-109 must incorporate HEPES at 20 mM (14-22 mM; this is critical to its function with the other ingredients. Table II presents typical results of clonal growth experiments showing that the design of HECK-109 supports a higher growth rate and a higher colony forming efficiency than a standard MCDB 153 commercial medium.
At this point, I wish to stress those novel aspects of the HECK-109 basal nutrient medium and, to discuss subsequent discoveries. The most significant discovery is that the concentration of HEPES (20 mM) in HECK 109 medium results in a 2 to 3 fold higher colony forming efficiency than that previously attainable. The second discovery is that an osmolarity of 300 mOsM of the medium permits attainment of higher saturation densities at confluence of monolayer culture. The third discovery is that it is necessary to provide the indicated concentrations of 6 key amino acids present in Stock 1 (2 to 5 times higher concentration than that in commercially available in MCDB 153 medium). This allows normal human keratinocyte cultures to routinely achieve a cell density equal to or greater than 100,000 cells per cm 2 . Media HECK-109 incorporates these three discoveries in such a way that the newly designed formulation will now fully support the formation of a complete reformed human epidermis as detailed below.
TABLE II______________________________________Effect of Osmolarity and HEPES Concentrations on theGrowth Response of Normal Human Keratinocytes Growth Response HEPES NaCl Osmolarity (Colonies/dish)Culture media (mM) (mM) (mOsM) AHK.sup.a NHK.sup.b______________________________________MCDB-153 28 130 340 84 ± 12 275 ± 24HECK-109 23 104 300 196 ± 23 438 ± 35______________________________________ .sup.a Secondary cultures of adult skin normal human keratinocytes (AHK) were seeded at 2 × 10.sup.3 cells/dish in MCDB 153 medium and refed HECK109 48 hours later. Dishes were fixed for colony counts 6 days later. .sup.b Clonal growth experiments were performed on neonatal foreskin secondary normal human keratinocytes (NHK) cultures as described in Wille J. J., et al., J. Cellular Physiol. 121:31-44 (1984).
EXAMPLE 3
Clonal Growth Studies Employing Single Cell Clones in HECK-109Medium
Normal human keratinocyte cultures were routinely initiated, from either foreskin or adult female breast skin, as detailed above in Example 1, and then placed into secondary culture in complete HECK-109FS medium. The purpose of the following experiment was to determine the colony forming ability of individual keratinocyte stem cells obtained from different skin donors and from different passage levels of the same normal human keratinocyte sample. It is stressed here that each culture was established from a single genetic source to ensure that the responses observed represent only deliberate experimental manipulations. The technique of cloning individual cells was accomplished by seeding 1000 cells from a exponentially dividing parent culture into a 100 mm 2 Petri dish containing prewarmed HECK-109FS medium. The dish had been pre-seeded with a large number of sterile cloning chips (0.4 cm 2 , Bellco Glass Company, Vineland, N.J., U.S.A.). Individual glass chips were screened microscopically with an inverted phase contrast microscope and only those bearing a single cell were selected and placed into a sterile 35 cm 2 petri dish and refed fresh HECK-109FS medium. Visual observations of each such single cell isolate were made and a daily record of the number of cell s formed from each single-celled clone. The results of these experiments are as set forth in Tables III and IV. The data show that each proliferating basal cell from a given donor culture has an exceedingly high clonogenic potential.
Typically, a clone is comprised of more than 1000 cells, indicating that the original single cell had undergone more than 10 doublings. Such clones are, by definition, basal stem cells and data on their clonal analysis is presented in Tables III and IV. The results in Table III show that 70 percent of single cells derived from a third passage neonatal foreskin normal human keratinocyte cultures were, in fact, keratinocyte stem cells. Adult-derived normal human keratinocyte secondary cultures also at the third passage level had a significantly reduced clonogenic potential (48 percent), which correlates with the slower growth rate (48 hour doubling time) of the parent culture, which when compared with the rapid (24 hour doubling time) of the neonatal foreskin normal human keratinocyte culture clearly shows that the proliferative potential of stem cells is determined by prior culture conditions. Table IV presents data comparing five different neonatal foreskin normal human keratinocyte cultures and shows again, the fact that a consistently high clonogenic potential is maintained in secondary cultures under prior culture conditions.
TABLE III______________________________________Comparison of the Proliferative Potential of IndividualAdult Versus Neonatal Keratinocyte Basal CellsPrior Culture Condition.sup.a, bCloneNo. Passage Density % ProliferativeClones (N) No. (10.sup.4 /cm.sup.2) Average GT (hrs)______________________________________Adult 3 0.4 48 48(109)Neonatal 3 7.5 24 70(106)______________________________________ .sup.a GT is defined as the average population doubling time (in hours) o the culture. .sup.b N is the number of single cell clones tested.
TABLE IV______________________________________Clonal Analysis of the Proliferative Potentialof Individual Keratinocyte Basal CellsNeonatalClone Prior Culture Condition.sup.a,bProliferative Passage Cell density Average %No. level (10.sup.4 /cm.sup.2) GT(hr) Clones(N)______________________________________1 2 1.87 24 (5).sup.c 75 (32)1 3 1.73 24 (6) 66 (35)2 2 1.0 24 (4) 79 (34)3 2 1.1 24 (6) 68 (37)4 2 0.65 30 (4) 51 (93) Mean % = 63(231)______________________________________ .sup.1 GT is defined as the average population doubling time (in hours) o the culture. .sup.b N is the number of single cell colonies tested. .sup.c The number in parentheses within this column indicates the age of the parent culture in days.
In summary, the combined results of 231 single cells cloned at random from secondary cultures reared in HECK-109FS medium showed that at least 63 percent were keratinocyte stem cells. The results of these single cell clonal studies indicate that the novel basal medium HECK-109 supports increased clonal growth of basal cells and enhances their clonogenic potential 10 times above the reported values obtained by Green, H. and Rheinwald, J. (U.S. Pat. No. 4,016,036, 1980) or in the serum-free culturing process of Boyce, S. T. and Ham, R. G. (U.S. Pat. No. 4,673,649, 1986). These considerations are of utmost relevance to the claims of this patent and for the purpose of obtaining a commercially usable in vitro manufactured living skin substitute.
EXAMPLE 4
Steps for the Formation of a Complete Epidermis in the
Serum-Free HECK-109 Culture Medium The formation of a complete reformed human epidermis in serum-free HECK-109 medium is accomplished in three separate culture phases. Phase I of culture begins with the seeding of basal keratinocyte stem cells into culture dishes (the number and size of the culture dishes is only limited by the absolute number of cells obtained in the preceding normal human keratinocyte early passage culture) at a cell density of approximately a 1000 cells per cm 2 . Typically, several million keratinocyte stem cells can be prepared from a single primary culture flask, representing about a 5000-fold increase in cells over the starting stem cells recovered from the skin sample. All normal human keratinocyte cultures are fed complete HECK-109FS medium, i.e., basal HECK-109 supplemented with phosphoethanolamine=0.1 mM (0.05-0.20); ethanolamine=0.1 mM (0.05-0.20); hydrocortisone=0.5 μM (0.1-1.0); EGF=10 ng/ml (1-25); IGF-1=5 ng/ml (0.3-30.0). Cultures are refed fresh medium every other day until the cell density equals 1 to 2×10 4 cells per cm 2 . The cultures are then refed HECK-109FS medium containing the following six key amino acids: Histidine=1.7 (0.5-2.5)×10 -4 M; Isoleucine=2.5 (0.5-5.0)×10 -4 M; Methionine=3.0 (1.0-5.0)×10 -4 M; Phenylalanine=3.0 (1.0-5.0)×10 -4 M; Tryptophan=2.0 (0.5-5.0)×10 -4 M; and Tyrosine=3.0 (1.0-5.0)×10 -4 M. Cultures refed this medium every other day routinely reach confluence in 6 to 10 days.
Phase II, the induction of the stratum spinosum and the stratum granulosum and concomitant maintenance of the stratum germinativum, begins with the removal of the amino acid-enriched HECK-109FS medium and its replacement with complete amino acid-enriched HECK-109DM medium containing 0.7 to 5 mH Ca 2+ and β-TGF (3 to 30 ng/ml). The removal of any one of the media a and its replacement with another media is preferably accomplished by any of the common, well-known ways culture media are replaced, such as by aspiration accomplished under sterile conditions. This treatment in low density culture results in a parasynchronous growth arrest in the G 1 phase of the cell cycle (Shipley, G. D., et al., Cancer Res. 46:2068-2071 (1986) and Wilke, M., et al., Amer. J. Pathol. 131:171-181 (1988)). However, the addition of β-TGF to proliferating monolayer cultures which have attained confluence and which are still dividing, induces, within 48-96 hr, a progressive stratification of the basal cells to form a multilayered epithelium. Concomitantly, the clonogenic potential of the culture declines to approximately 50 percent. By the combined addition of β-TGF, and EGF, a fraction of the dividing basal cells is repressed, and the remaining basal cells, which have already entered into the succeeding cell cycle, are committed to form suprabasal cells. The latter progressively enlarge, differentiate into cell types representative of the spinous and granular cell layers, and migrate to the upper layers of the multilayered epidermis where they are shed into the medium. The result of this differentiation process is the formation of an extended sheet of multilayered epidermis. This process takes several days to a week to complete, and results in an incomplete living epidermis comprised of a basal cell layer with an overlying Malpighiian cell layer (stratum germinativum+stratum spinosum).
The final step of the of culture process (Phase III) converts the incomplete epidermis to a complete human epidermis by induction in the uppermost layers of a cornified cell layer stratum lucidum, stratum corneum, and stratum disjunction. This step is accomplished by removal of the amino acid-enriched HECK-109DM medium containing β-TGF, EGF and 0.7 to 5 mM Ca 2+ and its replacement with HECK-109CM, i.e. amino acid-enriched basal HECK-109 medium supplemented with 0.7 or 5 mM Ca 2+ , 5 μg linoleic acid (1-15 μg/ml); 0.1 mM phosphoethanolamine (0.05-0.20 mM); 0.1 mM ethanolamine (0.05-0.20 mM); and 0.5 μM hydrocortisone (0.1-1.0 μM). During Phase III of culture, granular cells continue to mature into cornified, anucleate cells which form the topmost layer of the completed epidermis.
Thus it can be appreciated from the foregoing that this invention discloses a method for the formation of a histologically-complete skin substitute comprising the steps of: 1) feeding basal keratinocyte stem cells a medium comprising N-(2-OH-ethyl-)piperazine-N'-(2-ethane-sulfonic acid) in a concentration in the range of 14 mM to 22 mM, sodium chloride in a concentration in the range of 90 mM to 140 mM, calcium 2+ ion in a concentration in the range of 0.03 mM to 0.3 mM, histidine in a concentration in the range of 1.0×10 -4 M to 2.5×10 -4 M, isoleucine in a concentration in the range of 0.5×10 -4 M to 5.0×10 -4 M, methionine in a concentration in the range of 1.0×10 -4 M to 5.0×10 -4 M, phenylalanine in a concentration in the range of 1.0×10 -4 M to 5.0×10 -4 M, tryptophan in a concentration in the range of 0.5×10 -4 M to 5.0×10 -4 M, tyrosine in a concentration in the range of 1.0×10 -4 M to 5.0×10 -4 M, hydrocortisone in a concentration in the range of 1.0×10 -7 M to 5.0×10 -7 M, phosphoethanolamine in a concentration in the range of 0.5×10 -4 M to 2.0×10 -4 M, ethanolamine in a concentration in the range of 0.5×10 -4 M to 2.0×10 -4 M, epidermal growth factor in a concentration in the range of 1 ng/ml to 25 ng/ml, and insulin-like growth factor-1 in a concentration in the range of 0.3 ng/ml to 30 ng/ml; 2)the replacement of the preceding medium with a medium comprising N-(2-OH-ethyl-)piperazine-N'-(2-ethane-sulfonic acid) in a concentration in the range of 14 mM to 22 mM, sodium chloride in a concentration in the range of 90 mM to 140 mM, calcium 2+ ion in a concentration in the range of 0.7 mM to 3.0 mM, histidine in a concentration in the range of 1.0×10 -4 M to 2.5×10 -4 M, isoleucine in a concentration in the range of 0.5×10 -4 M to 5.0×10 -4 M, methionine in a concentration in the range of 1.0×10 -4 M to 5.0×10 -4 M, phenylalanine in a concentration in the range of 1.0×10 -4 M to 5.0×10 -4 M, tryptophan in a concentration in the range of 0.5×10 -4 M to 5.0×10 -4 M, tyrosine in a concentration in the range of 1.0×10 -4 M to 5.0×10 -4 M, hydrocortisone in a concentration in the range of 1.0×10 -7 M to 10.0×10 -7 M, phosphoethanolamine in a concentration in the range of 0.5×10 -4 M to 2.0×10 -4 M, ethanolamine in a concentration in the range of 0.5×10 -4 M to 2.0×10 -4 M, epidermal growth factor in a concentration in the range of 1 ng/ml to 5 ng/ml, insulin-like growth factor-1 in a concentration in the range of 0.3 ng/ml to 30 ng/ml, and Beta-transforming growth factor in a concentration in the range of 3.0 ng/ml to 30 ng/ml; and 3) the replacement of the preceding medium with a medium comprising N-(2-OH-ethyl-ipiperazine-N'-(2-ethane-sulfonic acid)in a concentration in the range of 14 mM to 22 mM, sodium chloride in a concentration in the range of 90 mM to 140 mM, calcium 2+ ion in a concentration in the range of 0.7 mM to 3.0 mM, histidine in a concentration in the range of 1.0×10 -4 M to 2.5×10 -4 M, isoleucine in a concentration in the range of 0.5×10 -4 M to 5.0×10 -4 M, methionine in a concentration in the range of 1.0×10 -4 M to 5.0×10 -4 M, phenylalanine in a concentration in the range of 1.0×10 -4 M to 5.0×10 -4 M, tryptophan in a concentration in the range of 0.5×10 -4 M to 5.0×10 -4 M, tyrosine in a concentration in the range of 1.0×10 -4 M to 5.0×10 -4 M, linoleic acid in a concentration in the range of 1 microgram/ml to 15 microgram/ml, hydrocortisone in a concentration in the range of 1.0×10 -7 M to 10.0×10 -7 M, phosphoethanolamine in a concentration in the range of 0.5×10 -4 M to 2.0×10 -4 M, and ethanolamine in a concentration in the range of 0.5×10 -4 M to 2.0×10 -4 M.
More preferably, the method for the formation of a histologically-complete skin substitute includes in the first step the concentration of N-(2-OH-ethyl-)piperazine-N'-(2-ethane-sulfonic acid)in the range of 14 mM to 22 mM, the concentration of sodium chloride in the range of 90 mM to 140 mM, the concentration of calcium 2+ ion in the range of 0.1 mM to 0.15 mM, the concentration of histidine in the range of 1.0×10 -4 M to 2.5×10 -4 M, the concentration of isoleucine in the range of 0.5×10 -4 M to 5.0×10 -4 M, the concentration of methionine in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of phenylalanine in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of tryptophan in the range of 0.5×10 -4 M to 5.0×10 -4 M, the concentration of tyrosine in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of hydrocortisone in the range of 1.0×10 -7 M to 2.0×10 -7 M, the concentration of phosphoethanolamine in the range of 0.7×10 -4 M to 1.5×10 -4 M, the concentration of ethanolamine in the range of 0.7×10 -4 M to 1.5×10 -4 M, the concentration of epidermal growth factor in the range of 1 ng/ml to 5 ng/ml, and the concentration of insulin-like growth factor-1 in the range of 0.3 ng/ml to 3 ng/ml. In the second step the concentration of N-(2-OH-ethyl-)piperazine-N'-(2-ethane-sulfonic acid) is in the range of 14 mM to 22 mM, the concentration of sodium chloride is in the range of 90 mM to 140 mM, the concentration of calcium 2+ ion is in the range of 1.2 mM to 2.5 mM, the concentration of histidine is in the range of 1.0×10 -4 M to 2.5×10 -4 M, the concentration of isoleucine is in the range of 0.5×10 -4 M to 5.0×10 -4 M, the concentration of methionine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of phenylalanine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of tryptophan is in the range of 0.5×10 -4 M to 5.0×10 -4 M, the concentration of tyrosine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of hydrocortisone is in the range of 1.0×10 -7 M to 5.0×10 -7 M, the concentration of phosphoethanolamine is in the range of 0.7×10 -4 M to 1.5×10 -4 M, the concentration of ethanolamine is in the range of 0.7×10 -4 M to 1.5×10 -4 M, the concentration of epidermal growth factor is in the range of 1 ng/ml to 3 ng/ml, the concentration of insulin-like growth factor-1 is in the range of 0.3 ng/ml to 3 ng/ml, and the concentration of Beta-transforming growth factor is in the range of 15 ng/ml to 25 ng/ml. And in the third step the concentration of N-(2-OH-ethyl-)piperazine-N'-(2-ethane-sulfonic acid) is in the range of 14 mM to 22 mM, the concentration of sodium chloride is it, the range of 90 mM to 40 mM, the concentration of calcium 2+ ion is in the range of 1.2 mM to 2.5 mM, the concentration of histidine is in the range of 1.0×10 -4 M to 2.5×10 -4 M, the concentration of isoleucine is in the range of 0.5×10 -4 M to 5.0×10 -4 M, the concentration of methionine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of phenylalanine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of tryptophan is in the range of 0.5×10 -4 M to 5.0×10 -4 M, and the concentration of tyrosine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of linoleic acid is in the range of 7 ml crogram/ml to 12 microgram/ml, the concentration of hydrocortisone is in the range of 1.0×10 -7 M to 2.0×10 -7 M, the concentration of phosphoethanolamine is in the range of 0.7×10 -4 M to 1.5×10 -4 M, and the concentration of ethanolamine is in the range of 0.7×10 -4 M to 1.5×10 -4 M.
The method for the formation of a histologically-complete skin substitute set forth above may include the use of modified concentrations of various components. In one such usage involving modified concentrations, in the first step the concentration of N-(2-OH-ethyl-)piperazine-N'-(2-ethane-sulfonic acid) is in the range of 14 mM to 22 mM, the concentration of sodium chloride is in the range of 90 mM to 140 mM, the concentration of calcium 2+ ion is approximately 0.8 mM, the concentration of histidine is in the range of 1.0×10 -4 M to 2.5×10 -4 M, the concentration of isoleucine is in the range of 0.5×10 -4 M to 5.0×10 -4 M, the concentration of methionine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of phenylalanine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of tryptophan is in the range of 0.5×10 -4 M to 5.0×10 -4 M, the concentration of tyrosine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of hydrocortisone is approximately 1.5×10 -7 M, the concentration of phosphoethanolamine is approximately 1.0×10 -4 M, the concentration of ethanolamine is approximately 1.0×10 -4 M, the concentration of epidermal growth factor is approximately 1 ng/ml, and the concentration of insulin-like growth factor-1 is approximately 3 ng/ml, in the second step the concentration of N-(2-OH-ethyl-)piperazine-N'-(2-ethane-sulfonic acid) is in the range of 14 mM to 22 mM, the concentration of sodium chloride is in the range of 90 mM to 140 mM, the concentration of calcium 2+ ion is approximately 1.8 mM, the concentration of histidine is in the range of 1.0×10 -4 M to 2.5×10 -4 M, the concentration of isoleucine is in the range of 0.5×10 -4 M to 5.0×10 -4 M, the concentration of methionine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of phenylalanine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of tryptophan is in the range of 0.5×10 -4 M to 5.0×10 -4 M, the concentration of tyrosine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of hydrocortisone is approximately 1.5×10 -4 M, the concentration of phosphoethanolamine is approximately 1.0×10 -4 M, the concentration of ethanolamine is approximately 1.0×10 -4 M, the concentration of epidermal growth factor is approximately 1 ng/ml, the concentration of insulin-like growth factor-1 is approximately 0.3 ng/ml, and the concentration of Beta-transforming growth factor is approximately 20 ng/ml, and in the third step the concentration of N-(2-OH-ethyl-)piperazine-N'-(2-ethane-sulfonic acid) is in the range of 14 mM to 22 mM, the concentration of sodium chloride is in the range of 90 mM to 140 mM, the concentration of calcium 2+ ion is approximately 1.8 mM, the concentration of histidine is in the range of 1.0×10 -4 M to 2.5×10 -4 M, the concentration of isoleucine is in the range of 0.5×10 -4 M to 5.0×10 -4 M, the concentration of methionine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of phenylalanine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of tryptophan is in the range of 0.5×10 -4 M to 5.0×10 -4 M, and the concentration of tyrosine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of linoleic acid is approximately 10 microgram/ml, the concentration of hydrocortisone is approximately 2.0×10 -7 M, the concentration of phosphoethanolamine is approximately 1.0×10 -4 M, and the concentration of ethanolamine is approximately 1.0×10 -4 M.
The method for the formation of a histologically-complete skin substitute set forth above may also include an additional step, namely the step of initially treating basal keratinocyte cells to increase clonal growth with a medium comprising N-(2-OH-ethyl-)piperazine-N'-(2-ethane-sufonic acid) which is in a concentration in the range of 14 mM to 22 mM, sodium chloride which is in a concentration in the range of 90 mM to 140 mM, calcium 2+ ion which is in a concentration in the range of 0.03 mM to 0.3 mM, histidine which is in the concentration in the range of 1.0×10 -4 M to 2.5×10 -4 M, isoleucine which is in a concentration in the range of 0.5×10 -4 M to 5.0×10 -4 M, methionine which is in a concentration in the range of 1.0×10 -4 H to 5.0×10 -4 M, pbenylalanine which is in a concentration in the range of 1.0×10 -4 M to 5.0×10 -4 M, tryptophan which is in a concentration in the range of 0.5×10 -4 M to 5.0×10 -4 M, and tyrosine which is in a concentration in the range of 1.0×10 -4 M to 5.0×10 -4 M.
If the additional step is used in the method for the formation of a histologically-complete skin substitute, the concentrations of the components may be modified such that the basal keratinocyte cells are initially treated with a medium in which concentration of N-(2-OH-ethyl)piperazine-N'-(2-ethane-sulfonic acid) is in the range of 16 mM to 20 mM, the concentration of sodium chloride is in the range of 100 mM to 120 mM, the concentration of calcium 2+ ion is in the range of 0.05 mM to 0.15 mM, the concentration of histidine is in the range of 1.5×10 -4 M to 2.0×10 -4 M,, the concentration of isoleucine is in the range of 1.5×10 -4 M to 3.0×10 -4 M, the concentration of methionine is in the range of 2.0×10 -4 M to 4.0×10 -4 M, the concentration of phenylalanine is in the range of 2.0×10 -4 M to 4.0×10 -4 M, the concentration of tryptophan is in the range of 1.5×10 -4 M to 2.5×10 -4 M, and the concentration of tyrosine is in the range of 2.0×10 -4 M to 4.0×10 -4 M.
If the additional step is used in the method for the formation of a histologically-complete skin substitute, the concentrations of the components may be modified such that the basal keratinocyte cells are initially treated with a medium in the basal keratinocyte cells are initially treated with a medium in which concentration of N-(2-OH-ethyl-)piperazine-N'-(2-ethane-sulfonic acid) is approximately 20 mM, the concentration of sodium chloride is approximately 113 mM, the concentration of calcium 2+ ion is approximately 0.125 mM, the concentration of histidine is approximately 1.7×10 -4 M, the concentration of isoleucine is approximately 2.5×10 -4 M, the concentration of methionine is approximately 3.0×10 -4 M, the concentration of phenylalanine is approximately 3.0×10 -4 M, the concentration of tryptophan is approximately 2.0×10 -4 M, and the concentration of tyrosine is in the range of 3.0×10 -4 M.
There is also disclosed a serum-free medium for use in the formation of a histologically-complete skin substitute comprising N-(2-OH-ethyl-)piperazine-N'-(2-ethane-sulfonic acid), sodium chloride, calcium 2+ ion, histidine, isoleucine, methionine, phenylalanine, tryptophan, tyrosine, hydrocortisone, phosphoethanolamine, ethanolamine, epidermal growth factor, and insulin-like growth factor-1.
In the above medium the concentration of N-(2-OH-ethyl-)piperazine-N'-(2-ethane-sulfonic acid) is in the range of 14 mM to 22 mM, the concentration of sodium chloride is in the range of 90 mM to 140 mM, the concentration of calcium 2+ ion is in the range of 0.03 mM to 0.3 mM, the concentration of histidine is in the range of 1.0×10 -4 M to 2.5×10 -4 M, the concentration of isoleucine is in the range of 0.5×10 -4 M to 5.0×10 -4 M, the concentration of methionine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of phenylalanine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of tryptophan is in the range of 0.5×10 -4 M to 5.0×10 -4 M, the concentration of tyrosine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of hydrocortisone is in the range of 1.0×10 -7 M to 5.0×10 -7 M, the concentration of phosphoethanolamine is in the range of 0.5×10 -4 M to 2.0×10 -4 M, the concentration of ethanolamine is in the range of 0.5×10 -4 M to 2.0×10 -4 M, the concentration of epidermal growth factor is in the range of 1 ng/ml to 25 ng/ml, and the concentration of insulin-like growth factor-1 is in the range of 0.3 ng/ml to 30 ng/ml.
In a modified composition of the above medium, the concentration of N-(2-OH-ethyl-)piperazine-N'-(2-ethane-sulfonic acid) is in the range of 14 mM to 22 mM, the concentration of sodium chloride is in the range of 90 mM to 140 mM, the concentration of calcium 2+ ion is in the range of 0.1 mM to 0.15 mM, the concentration of histidine is in the range of 1.0×10 -4 M to 2.5×10 -4 M, the concentration of isoleucine is in the range of 0.5×10 -4 M to 5.0×10 -4 M, the concentration of methionine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of phenylalanine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of tryptophan is in the range of 0.5×10 -4 M to 5.0×10 -4 M, the concentration of tyrosine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of hydrocortisone is in the range of 1.0×10 -7 M to 2.0×10 -7 M, the concentration of phosphoethanolamine is in the range of 0.7×10 -4 M to 1.5×10 -4 M, the concentration of ethanolamine is in the range of 0.7×10 -4 M to 1.5×10 -4 M, the concentration of epidermal growth factor is in the range of 1 ng/ml to 5 ng/ml, and the concentration of insulin-like growth factor-1 is in the range of 0.3 ng/ml to 3 ng/ml.
In yet another modified composition of the above medium the concentration of N-(2-OH-ethyl-)piperazine-N'-(2-ethane-sulfonic acid) is in the range of 14 mM to 22 mM, the concentration of sodium chloride is in the range of 90 mM to 40 mM, the concentration of calcium 24 ion is approximately 0.125 mM, the concentration of histidine is in the range of 1.0×10 -4 M to 2.5×10 -4 M, the concentration of isoleucine is in the range of 0.5×10 -4 M to 5.0×10 -4 M, the concentration of methionine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of phenylalanine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of tryptophan is in the range of 0.5×10 -4 M to 5.0×10 -4 M, the concentration of tyrosine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of hydrocortisone is approximately 1.5×10 -7 M, the concentration of phosphoethanolamine is approximately 1.0×10 -4 M, the concentration of ethanolamine is approximately 1.0×10 -4 M, the concentration of epidermal growth factor is approximately 1 ng/ml, and the concentration of insulin-like growth factor-1 is approximately 3 ng/ml.
There is also disclosed a serum-free medium for use in the formation of a histologically-complete skin substitute comprising N-(2-OH-ethyl-)piperazine-N'-(2-ethane-sulfonic acid), sodium chloride, calcium 2+ ion, histidine, isoleucine, methionine, phenylalanine, tryptophan, tyrosine, hydrocortisone, phosphoethanolamine, ethanolamine, epidermal growth factor, insulin-like growth factor-1, and Beta-transforming growth factor.
In the above medium the concentration of N-(2-OH-ethyl-)piperazine-N'-(2-ethane-sulfonic acid) is in the range of 14 mM to 22 mM, the concentration of sodium chloride is in the range of 90 mM to 140 mM, the concentration of calcium 2+ ion is in the range of 0.7 mM to 3.0 mM, the concentration of histidine is in the range of 1.0×10 -4 M to 2.5×10 -4 M, the concentration of isoleucine is in the range of 0.5×10 -4 M to 5.0×10 -4 M, the concentration of methionine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of phenylalanine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of tryptophan is in the range of 0.5×10 -4 M to 5.0×10 -4 M, the concentration of tyrosine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of hydrocortisone is in the range of 1.0×10 -7 M to 10.0×10 -7 M, the concentration of phosphoethanolamine is in the range of 0.5×10 -4 M to 2.0×10 -4 M, the concentration of ethanolamine is in the range of 0.5×10 -4 M to 2.0×10 -4 M, the concentration of epidermal growth factor is in the range of 1 ng/ml to 5 ng/ml, the concentration of insulin-like growth factor-1 is in the range of 0.3 ng/ml to 30 ng/ml, and the concentration of Beta-transforming growth factor is in the range of 3.0 ng/ml to 30 ng/ml.
In a modified composition of the above medium, the concentration of N-(2-OH-ethyl-)piperazine-N'-(2-ethane-sulfonic acid) is in the range of 14 mM to 22 mM, the concentration of sodium chloride is in the range of 90 mM to 140 mM, the concentration of calcium 2+ ion is in the range of 1.2 mM to 2.5 mM, the concentration of histidine is in the range of 1.0×10 -4 M to 2.5×10 -4 M, the concentration of isoleucine is in the range of 0.5×10 -4 M to 5.0×10 -4 M, the concentration of methionine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of phenylalanine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of tryptophan is in the range of 0.5×10 -4 M to 5.0×10 -4 M, the concentration of tyrosine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of hydrocortisone is in the range of 1.0×10 -7 M to 5.0×10 -7 M, the concentration of phosphoethanolamine is in the range of 0.7×10 -4 M to 1.5×10 -4 M, the concentration of ethanolamine is in the range of 0.7×10 -4 M to 1.5×10 -4 M, the concentration of epidermal growth factor is in the range of 1 ng/ml to 3 ng/ml, the concentration of insulin-like growth factor-1 is in the range of 0.3 ng/ml to 3 ng/ml, and the concentration of Beta-transforming growth factor is in the range of 15 ng/ml to 25 ng/ml.
In yet another modified composition of the above medium the concentration of N-(2-OH-ethyl-)piperazine-N'-(2-ethane-sulfonic acid) is in the range of 14 mM to 22 mM, the concentration of sodium chloride is in the range of 90 mM to 140 mM, the concentration of calcium 2+ ion is approximately 1.8 mM, the concentration of histidine is in the range of 1.0×10 -4 M to 2.5×10 -4 M, the concentration of isoleucine is in the range of 0.5×10 -4 M to 5.0×10 -4 M, the concentration of methionine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of phenylalanine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of tryptophan is in the range of 0.5×10 -4 M to 5.0×10 -4 M, the concentration of tyrosine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of hydrocortisone is approximately 1.5×10 -7 M, the concentration of phosphoethanolamine is approximately 1.0×10 -4 M, the concentration of ethanolamine is approximately 1.0×10 -4 M, the concentration of epidermal growth factor is approximately 1 ng/ml, the concentration of insulin-like growth factor-1 is approximately 0.3 ng/ml, and the concentration of Beta-transforming growth factor is approximately 20 ng/ml.
There is also disclosed a serum-free medium for use in the formation of a histologically-complete skin substitute comprising N-(2-OH-ethyl-)piperazine-N'-(2-ethane-sulfonic acid), sodium chloride, calcium 2+ ion, histidine, isoleucine, methionine, phenylalanine, tryptophan, tyrosine, linoleic acid, hydrocortisone, phosphoethanolamine, and ethanolamine.
In the above medium the concentration of N-(2-OH-ethyl-)piperazine-N'-(2-ethane-sulfonic acid) is in the range of 14 mM to 22 mM, the concentration of sodium chloride is in the range of 90 mM to 140 mM, the concentration of calcium 2+ ion is in the range of 0.7 mM to 3.0 mM, the concentration of histidine is in the range of 1.0×10 -4 M to 2.5×10 -4 M, the concentration of isoleucine is in the range of 0.5×10 -4 M to 5.0×10 -4 M, the concentration of methionine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of phenylalanine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of tryptophan is in the range of 0.5×10 -4 M to 5.0×10 -4 M, the concentration of tyrosine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of linoleic acid is in the range of 1 microgram/ml to 15 microgram/ml, the concentration of hydrocortisone is in the range of 1.0×10 -7 M to 10.0×10 -7 M, the concentration of phosphoethanolamine is in the range of 0.5×10 -4 M to 2.0×10 -4 M, and the concentration of ethanolamine is in the range of 0.5×10 -4 M to 2.0×10 -4 M.
In a modified composition of the above medium, the concentration of N-(2-OH-ethyl-)piperazine-N'-(2-ethane-sulfonic acid) is in the range of 14 mM to 22 mM, the concentration of sodium chloride is in the range of 90 mM to 140 mM, the concentration of calcium 2+ ion is in the range of 1.2 mM to 2.5 mM, the concentration of histidine is in the range of 1.0×10 -4 M to 2.5×10 -4 M, the concentration of isoleucine is in the range of 0.5×10 -4 M to 5.0×10 -4 M, the concentration of methionine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of phenylalanine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of tryptophan is in the range of 0.5×10 -4 M to 5.0×10 -4 M, and the concentration of tyrosine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of linoleic acid is in the range of 7 microgram/ml to 12 microgram/ml, the concentration of hydrocortisone is in the range of 1.0×10 -7 H to 2.0×10 -7 H, the concentration of phosphoethanolamine is in the range of 0.7×10 -4 M to 1.5×10 -4 M, and the concentration of ethanolamine is in the range of 0.7×10 -4 M to 1.5×10 -4 M.
In yet another modified composition of the above medium the concentration of N-(2-OH-ethyl-)piperazine-N'-(2-ethane-sulfonic acid) is in the range of 14 mM to 22 mM, the concentration of sodium chloride is in the range of 90 mM to 140 mM, the concentration of calcium 2+ ion is approximately 1.8 mM, the concentration of histidine is in the range of 1.0×10 -4 M to 2.5×10 -4 M, the concentration of isoleucine is in the range of 0.5×10 -4 M to 5.0×10 -4 M, the concentration of methionine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the-concentration of phenylalanine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of tryptophan is in the range of 0.5×10 -4 M to 5.0×10 -4 M, and the concentration of tyrosine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of linoleic acid is approximately 10 microgram/ml, the concentration of hydrocortisone is approximately 2.0×10 -7 M, the concentration of phosphoethanolamine is approximately 1.0×10 -4 M, and the concentration of ethanolamine is approximately 1.0×10 -4 M.
There is also disclosed a serum-free medium for use in the formation of a histologically-complete skin substitute comprising N-(2-OH-ethyl-)piperazine-N'-(2-ethane-sulfonic acid), sodium chloride, calcium 2+ ion, histidine, isoleucine, methionine, phenylalanine, tryptophan, and tyrosine.
In the above medium the concentration of N-(2-OH-ethyl-)piperazine-N'-(2-ethane-sulfonic acid) is in the range of 14 mM to 22 mM, the concentration of sodium chloride is in the range of 90 mM to 140 mM, the concentration of calcium 2+ ion is in the range of 0.03 mM to 0.3 mM, the concentration of histidine is in the range of 1.0×10 -4 M to 2.5×10 -4 M, the concentration of isoleucine is in the range of 0.5×10 -4 M to 5.0×10 -4 M, the concentration of methionine is in the range of 1.0×10 -7 M to 5.0×10 -4 M, the concentration of phenylalanine is in the range of 1.0×10 -4 M to 5.0×10 -4 M, the concentration of tryptophan is in the range of 0.5×10 -4 M to 5.0×10 -4 M, and the concentration of tyrosine is in the range of 1.0×10 -4 M to 5.0×10 -4 M.
In a modified composition of the above medium, the concentration of N-(2-OH-ethyl-piperazine-N'-(2-ethane-sulfonic acid) is in the range of 16 mM to 20 mM, the concentration of sodium chloride is in the range of 100 mM to 120 mM, the concentration of calcium 2+ ion is in the range of 0.05 mM to 0.15 mM, the concentration of histidine is in the range of 1.5×10 -4 M to 2.0×10 -4 M, the concentration of isoleucine is in the range of 1.5×10 -4 M to 3.0×10 -4 M, the concentration of methionine is in the range of 2.0×10 -4 M to 4.0×10 -4 M, the concentration of phenylalanine is in the range of 2.0×10 -4 M to 4.0×10 -4 M, the concentration of tryptophan is in the range of 1.5×10 -4 M to 2.5×10 -4 M, and the concentration of tyrosine is in the range of 2.0×10 -4 M to 4.0×10 -4 M.
In yet another modified composition of the above medium the concentration of N-(2-OH-ethyl-)piperazine-N'-(2-ethane-sulfonic acid) is approximately 20 mM, the concentration of sodium chloride is approximately 113 mM, the concentration of calcium 2+ ion is approximately 0.125 mM, the concentration of histidine is approximately 1.7×10 -4 M, the concentration of isoleucine is approximately 2.5×10 -4 M, the concentration of methionine is approximately 3.0×10 -4 M, the concentration of phenylalanine is approximately 3.0×10 -4 M, the concentration of tryptophan is approximately 2.0×10 -4 M, and the concentration of tyrosine is in the range of 3.0×10 -4 M.
EXAMPLE 5
Applications of Reformed Human Epidermis as a Living Skin Substitute
From previous studies in the literature it is widely known that human skin is a target organ for certain sex steroid hormones. In fact, skin is the next most active site after the liver for the metabolic interconversions of steroid hormones. Nevertheless, little is known about the direct effect of sex steroid hormones such as testosterone, progesterone and estrogens on the growth and differentiation of normal human keratinocytes.
A. Effect of sex steroid hormones on basal epidermal cells cultured in serum-free medium.
It has been reported (Peehl, D. M. and Ham, R. G., In Vitro 16:516-525 (1980) that, 17-β-estradio! stimulated the growth of epidermal cells in culture. However, the stimulatory effect that was observed was minimal and occurred under less than optimal clonal growth conditions. To whit, the medium employed and the growth factors present in that medium were not the media in which serum-free growth occurs under completely defined conditions. In view of these considerations, and because living skin substitutes are an ideal model for assaying the effects of sex steroid hormones it was important to reassess the effects of sex steroid hormones in HECK-109 medium containing only defined components and supplements. This example (5A) details my findings of the effect of testosterone, progesterone, 17-β-estradiol on the clonal growth of normal human keratinocytes in HECK-109FS. Table V present results which show that both progesterone (3.7×10 -6 M) and 17-β-estradiol (3.4×10 -6 M) exert an inhibitory action on the proliferation of basal keratinocylte stem cells derived from either newborn foreskin or adult breast skin. By contrast, testosterone (3.7×10 -6 M) has only a negligible effect on the clonal growth of these cells. Further, the results show that female-derived keratinocytes are less sensitive to the inhibitory effect of the female sex steroid hormones than are the male-derived keratinocytes (provided that the keratinocytes derived from adult skin are also for some unknown reason less sensitive than newborn). The above results imply that the normal pathways regulating keratinocyte proliferation may be profoundly perturbed by continuous exposure to progesterone or progesterone-related steroids, and therefore, these effects may need to be taken into account where reformed human epidermis is used as a model for the transdermal delivery of contraceptive steroids.
TABLE V______________________________________Effect of Estradiol, Progesterone, and Testosteroneon Clonal Growth of Normal Human Basal Keratinocytes Growth Responses.sup.a (colonies/dish)Culture conditions AH.sup.b NF.sup.c______________________________________HECK - 109FS medium 569 286 585 312+ Testosterone 603 259(1.0 μg/ml) 583 264+ Progesterone 311 58(1.0 μg/ml) 402 26+ Estradiol 426 83(1.0 μg/ml) 363 58______________________________________ .sup.a Values represent the results of duplicate determinations. .sup.b AH, adult skin keratinocytes were seeded at a density of 1000 cell per dish; the dishes were fixed and counted 10 days later. .sup.c NF, foreskin keratinocytes were seeded at a density of 500 cells per dish; the dishes were fixed and counted 10 days later.
B. Demonstration of specific and saturable 17-β-estradiol receptors in reformed human epidermis.
Human epidermis reformed in serum-free culture by the process steps outlined above, following removal from the culture preferably by any of the common, well-known ways that recovery is done, such as by treatment with a protease, can be used as a model system to assay the affect of a wide variety of test substances, e.g., hormones, toxins, viruses and carcinogens. Of immediate interest for the use of reformed human epidermis as a living skin substitute for transdermal delivery of contraceptive hormones is the question of whether reformed human epidermis has specific and saturable sex steroid hormone binding sites.
This example (5B) presents a series of experiments to measure the binding of radiolabelled 17-β-estradiol to replicate samples of human epidermis from a single genetic source. Reformed human epidermis was produced by culturing basal keratinocytes as outlined in Example 2 in replicate 24-well cluster dishes (Corning Tissue Culture Wares, Corning, N.Y.) through Phase III of culture. Several test wells were sampled at the time of the binding experiments by standard histological methods to verify that a complete epidermis had, indeed, been produced. The conditions of the binding assay were as follows: Phase III culture medium was aseptically removed and to the reformed human epidermis in each well 0.5 ml of CCS containing 10 to 50 nmol of radiolabelled 17-beta-estradiol (160 Ci/mM;0.2 μCi/ml) was added. The radiolabelled estradiol was purchased from New England Nuclear Corporation, Boston, Mass. The concentration of radiolabelled estradiol was fixed at half maximal saturation to assure effective competition with unlabelled identical and analogue steroid hormones over a wide range of competitor concentrations. The sex steroid competitors tested in the competition binding assay were 17-β-estradiol and other analogues such as testosterone, estriol, levonorgestral and norethisterone. At the end of the 20 hour incubation interval (at 4° C.) the radiolabelled solutions were removed, the surface of the reformed human epidermis samples rinsed gently with 1 ml of ice-cold CCS and 0.5 ml of Type IV collagenase (Dispase, 20 U/ml, Boehringer-Manheim, Los Angeles, Calif.) added to each well to enzymatically release the intact epidermal sheet. The released reformed human epidermis from each treatment well was transferred to its respective vial and the contained radioactivity was counted in a scintillation spectrometer.
Only 17-β-estradiol was an efficient competitor for the 17-β-estradiol receptor. Estriol, a close structural analog of estradiol also showed significant competition while testosterone and the progesterone analogues were not competitive. These results demonstrate that reformed human epidermis produced as intact epidermal sheets is a good model for biochemical assay of steroid sex hormone receptors and the results also provide direct evidence for the functional fidelity of reformed human epidermis as a living skin substitute.
INDUSTRIAL AND CLINICAL APPLICABILITY
The following claims are based on the five disclosures presented above in Examples 1 through 5. They include the design and formulation of the novel HECK 109 mediums which have been differently supplemented to provide for the serial achievement of the three-step cellular differentiation process of pluripotent basal cell keratinocytes to a fully differentiated human skin in vitro: i) HECK-109, the basal medium for cell starting; ii) HECK-109-fully supplemented (hereinafter referred to as HECK-109FS) for control over cellular growth; iii) HECK-109-differentiation medium (hereinafter referred to HECK-109DM) for the induction of differentiation and formation of a Malphigian layer; and iv) HECK-109-cornification medium (hereinafter referred to HECK-109CM) designed for the induction of cellular differentiation of a stratum lucidum, stratum corneum, and stratum disjunction in a pre-existing reformed epidermis produced by HECK-DH. The fifth and sixth claims involve the process for the sequential rendering of the culture process steps and the method of sequential control in the in vitro construction of a histologically-complete living skin substitute. These media and processes have application in in vitro testing of pharmaceuticals and topical drugs; screening of toxicants, carcinogens, complete or incomplete tumor promoters; evaluation of infective human agents including viruses, e.g. human papilloma viruses, Herpes-simplex viruses and Epstein-Barr virus; screening of cosmetics; production of keratinocyte products including protease inhibitors, growth factors, wound-healing factors, e.g. α, β-TGF and α-EGF, low-density lipoprotein receptors, laminins, fibronectins, retinoid receptors and binding proteins, steroid hormone receptors, transglutaminases, and cross-linking proteins of the cornified envelope; products for the abolition and/or prevention of wrinkles or screening of agents with potential for prevention of wrinkles; products for use in the introduction of immunizing agents into the recipient a reformed human epidermis graft or evaluation of cross-typing of donor-recipient tissues; and the use of autologously-derived cells for transplantation in the treatment of burns or other trauma. | Methods and formulations are disclosed for the in vitro formation of a histologically complete human epidermis in a serum-free, companion cell or cell feeder layer-free, and organotypic matrix-free culture system commencing with the isolation and cultivation of a unique population of clonally-competent basal epidermal cells and ending with the formation of a functional, histologically complete, human squamous epithelium. The formation of a histologically complete human epidermis is accomplished in a serum-free medium, without companion-cells or feeder layer cells or any organotypic support using a multi-step process that is controlled by manipulating the growth and differentiation factors requisite to the sequential development of a usable, functional, and completely differentiated epidermis. The entire culture process can be accomplished in a relatively short time (3 to 4 weeks) with complete reproducibility and can supply copious amounts (2 to 3 square meters) of viable reformed human epidermis for a variety of experimental, clinical and commercial purposes where a histologically-complete living skin substitute is required. | 79,043 |
This is a continuation of application Ser. No. 08/357,092 filed Dec. 15, 1994, which is a continuation of application Ser. No. 08/185,167 filed Jan. 24, 1994, which is a continuation of application Ser. No. 07/786,606 filed Nov. 1, 1991, all now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an autofocus camera in which focus is detected by either horizontal or vertical photoelectric conversion elements which are given priority.
2. Related Background Art
A known example of such autofocus cameras is disclosed in Japanese Patent Application Laid-open No. 62-95511. This autofocus camera is described below with reference to FIG. 1.
In FIG. 1, the subject light passed through a photographic lens 1 is passed through a cross-shaped opening 2a of a field mask 2 disposed at art expected focal plane of the photographic lens 1 and then through a capacitor lens 3 and four re-projecting lenses 4 to reach an image sensor 5. Two horizontal line image sensors (photoelectric conversion elements) 5a, 5b which are extended in the horizontal direction of a camera, and two vertical line image sensors (photoelectric conversion elements) 5c, 5d which are extended in the vertical direction of the camera are disposed on the image sensor 5. The light passed through the horizontal portion of the field mask opening 2a is received by the line image sensors 5a, 5b through the corresponding reprojecting lenses 4, and the light passed through the vertical portion of the opening 2a is received by the line image sensors 5c, 5d through the corresponding reprojecting lenses 4.
The horizontal portion of the opening 2a corresponds to a horizontal detecting region 61 which is horizontally extended on the photographing image plane 60 shown in FIG. 2, and the vertical portion of the opening 2a corresponds to a vertical detecting region 62 which is vertically extended. Thus, the subject light from the horizontal detecting region 61 is received by the horizontal line image sensors 5a, 5b, and the subject light from the vertical detecting region 62 is received by the vertical line image sensors 5c, 5d.
Each of the line image sensors 5a, 5b, 5c, 5d photoelectrically converts the subject light and provides an input signal to a focus detecting circuit (not shown). The focus detecting circuit calculates defocusing amount and direction from the input signal in order to drive the photographic lens 1 to the focusing position. The photographic lens 1 is focused on the basis of the defocusing amount and direction.
The advantages of the above arrangement comprising the horizontal and vertical line image sensors are described below.
In such a focus detection system, when a subject is parallel with the direction in which two line image sensors, i.e., a detecting region in the photographing image plane, are extended, since the output of the two line image sensors is flat without contrast, the defocusing amount and direction cannot be calculated, and the focus cannot be thus detected. The line image sensors are thus disposed in both the horizontal and vertical directions so that priority is given to the line image sensors in one (for example, the horizontal direction) of the two directions for detecting focus on the basis of the output thereof, and when the focus cannot be detected, the focus is detected on the basis of the output from the line image sensors in the other direction (vertical direction). This permits the focus to be surely detected regardless of the direction in which the subject is extended.
In such conventional autofocus cameras, since the line image sensors given priority are fixed, the direction of the sensors given priority, i.e., the direction of the detecting region given priority, with respect to the subject when the camera is in the horizontal attitude is different from that in the vertical attitude. For example, when priority is given to the horizontal line image sensors (horizontal detecting region 61), the detecting region 61 given priority is extended in the horizontal direction of the subject when the camera is in the horizontal attitude, while the detecting region 61 is extended in the vertical direction of the subject when the camera is in the vertical attitude.
It will be appreciated, of course, that when focus cannot be detected by using the line image sensors given priority, the time for focusing becomes longer. Thus, when the direction of the detecting region given priority with respect to the subject changes with changes in the attitude of the camera, as described above, there is the problem that the time for focusing the photographic lens when the subject is in the vertical attitude is different from that when the same subject is in the horizontal attitude.
SUMMARY OF THE INVENTION
In accordance with a first of its principal aspects, the present invention provides an autofocus camera which conducts a focus detection operation with one of differently directed sets of photoelectric conversion elements which is given priority according to the detected attitude of the camera. If focusing cannot be effected using the elements given priority, a focus detection operation is automatically conducted with the other elements.
In accordance with another of its principal aspects, the invention provides an auto focus camera in which each of differently directed first and second photoelectric conversion means includes a plurality of light-receiving elements. The camera has a first mode of operation in which focus detecting operations are conducted which collectively utilize outputs of all of the light-receiving elements when a first camera attitude is detected, and a second mode of operation in which focus detecting operations are conducted which collectively disregard the output of at least one such element when a second camera attitude is detected.
The various features and advantages of the present invention will be more fully appreciated from the following description of the embodiments illustrated in the accompanying drawings.
Although the present invention is described with reference to embodiments shown in the drawings, the invention is not limited to these embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing a focus detecting optical system;
FIG. 2 is a drawing showing focus detecting regions;
FIGS. 3 to 5 show an embodiment of the present invention, in which FIG. 3 is a block diagram showing the control system of an autofocus camera according to the invention, FIG. 4 is a drawing showing the relation of the attitude of a camera to the state of a mercury switch and the direction of a photographing image plane, and FIG. 5 is a flow chart showing the processing procedure;
FIGS. 6 to 9 show another embodiment of the invention, in which:
FIG. 6 is a drawing showing the arrangement of line image sensors;
FIG. 7 is a drawing showing focus detecting regions on a photographing image plane;
FIG. 8 is a flow chart showing the processing procedure; and
FIG. 9 is a drawing showing focus detecting regions on a photographing image plane when a person is photographed by a camera in the vertical attitude.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment in which the present invention is applied to an autofocus camera having the focus detecting optical system shown in FIG. 1 is described below with reference to FIGS. 3 to 5.
FIG. 3 is a block diagram showing the control system of an autofocus camera according to the present invention. A horizontal focus detecting circuit 22 and a vertical focus detecting circuit 23 are connected to a control circuit 21. The horizontal focus detecting circuit 22 performs a known focus detecting operation for calculating the defocusing amount and defocusing direction using the photoelectric conversion output from the horizontal line image sensors 5a, 5b shown in FIG. 1, both of which receives the subject light from the horizontal detecting regions 61 on the photographing image plane 60, so as to focus the photographing lens 1 on the subject. Similarly, the vertical focus detecting circuit 23 performs the focus detecting operation for calculating the defocusing amount and defocusing direction using the output from the vertical line image sensors 5c, 5d, both of which receive the subject light from the vertical detecting region 62 on the photographing image plane 60.
In this embodiment, the line image sensors corresponding to the focus detecting region extended in the horizontal direction of the subject are given priority for detecting the focus because the subject is generally frequently extended in the vertical direction rather than in the horizontal direction.
A indicating circuit 24, a lens driving circuit 25 and two mercury switches SW1, SW2 are also connected to the control circuit 21. A focusing motor 26 is connected to the lens driving circuit 25 so as to be driven in response to the command from the control circuit for focusing the photographing lens 1. The indicating circuit 24 indicates the impossibility of focusing by using a display (not shown) provided, for example, in a finder in response to the command from the control circuit 21.
The mercury switches SW1, SW2 are arranged substantially in the form of an invented V when the camera is in the normal horizontal attitude (in which the upper side of the camera body faces upward), as shown by (1) in FIG. 4. The on/off state of each of the mercury switches SW1, SW2 is changed as the mercury is gravitationally moved according to the attitude of the camera, as shown in FIG. 4. Namely, when the camera is in the attitude (horizontal attitude) shown by (1) in FIG. 4, both switches SW1, SW2 are turned off, and when the camera is in the attitude (vertical attitude) shown by (2), the switch SW1 is turned on, while the switch SW2 is turned off. In the attitude (vertical attitude) shown by (3), the switch SW1 is turned off, while the switch SW2 is turned on. In the attitude (horizontal attitude) shown by (4), both switches SW1, SW2 are turned on.
The procedure of the focusing control by the control circuit 21 is described below on the basis of the flow chart shown in FIG. 5.
For example, when a release button (not shown) is half pushed, the program shown in FIG. 5 is started. In Step S1, the attitude of the camera is first detected from the states of the mercury switches SW1, SW2. If both switches SW1, SW2 are turned on or off, it is decided that the camera is in the horizontal attitude, i.e., the attitude shown by (1) or (4) in FIG. 4, and the flow moves to Step S2 in which the horizontal focus detecting circuit 22 is started. The horizontal focus detecting circuit 22 reads the output of the horizontal line image sensors 5a, 5b, determines the defocusing amount and defocusing direction of the photographic lens by a known focus detecting operation on the basis of the output of the horizontal line image sensors 5a, 5b and inputs the defocusing amount and direction to the control circuit 21. When the defocusing amount and defocusing direction cannot be calculated because horizontal contrast is absent in the subject, a signal indicating the impossibility of focusing is input to the control circuit 21.
In Step S3, the control circuit 21 makes a decision on the basis of the output from the horizontal focus detecting circuit 22 whether or not the focus can be detected. If it is decided that the focus can be detected, in Step S4, a lens driving signal corresponding to the defocusing amount and direction is output to the lens driving circuit 25 so as to drive the photographic lens 1 toward the focusing position by using the motor 26. On the other hand, if it is decided in Step S3 that the focus cannot be detected, the flow moves to Step S5 in which the vertical focus detecting circuit 23 is started.
The vertical focus detecting circuit 23 detects the focus on the basis of the output from the vertical line image sensors 5c, 5d and inputs the defocusing amount and direction or the signal indicating the impossibility of focusing to the control circuit 21 in the same way as that described above. In Step S6, the control circuit 21 makes a decision on the basis of the input signal whether or not the focus can be detected. If it is decided that the focus can be detected, the flow moves to Step S4, while if it is decided that the focus cannot be detected, the flow moves to Step S11. In Step S11, a display signal is sent to the indicating circuit 24 so that the impossibility of focusing is indicated by the display (not shown),
On the other hand, in Step S1, if one of the two switches SW1, SW2 is turned on, and the other is turned off, it is decided that the camera is in the vertical attitude, i.e., the attitude shown by (2) or (3), and the flow moves to Step S7 in which the vertical focus detecting circuit 23 is started. In Step S8, a decision is made on the basis of the output from the vertical focus detecting circuit 23 whether or not the focus can be detected. If it is decided that the focus can be detected, in Step S4, the lens driving signal corresponding to the defocusing amount and direction, both of which are input from the vertical focus driving circuit 23, is output to the lens driving circuit 25 so as to drive the photographic lens 1 toward the focusing position by using the motor 26.
If it is decided in Step S8 that the focus cannot be detected, the flow moves to Step S9 in which the horizontal focus detecting circuit 22 is started. In Step S10, a decision is made on the basis of the signal from the horizontal focus detecting circuit 22 as to whether or not the focus can be detected. If it is decided that the focus can be detected, the flow moves to Step S4, while if it is decided that the focus cannot be detected, the flow moves to Step S11.
In detection of the focus according to the abovedescribed procedure, priority is given to the horizontal lime image sensors 5a, 5b when the camera is in the horizontal attitude, while priority is given to the vertical line image sensors 5c, 5d when the camera is in the vertical attitude. The shaded region in the photographing image plane 60 shown in FIG. 4 shows a detecting region corresponding to the line image sensors having priority. As shown in FIG. 4, the line image sensors given priority, i.e., the detecting region given priority, are constantly in the horizontal direction with respect to the subject regardless of the attitude of the camera. In the case of a vertical subject (ordinary case), the time required for focusing the photographic lens 1 can be minimized regardless of the attitude of the camera.
In this embodiment, the horizontal line image sensors 5a, 5b comprise horizontal photoelectric conversion elements, the vertical line image sensors 5c, 5d comprise vertical photoelectric conversion elements, the control circuit 21 and the horizontal and vertical focus detecting circuits 22, 23 comprise focus detecting devices, the lens driving circuit 25 and the motor 26 comprise lens driving devices and the mercury switches SW1, SW2 comprise attitude detecting devices, respectively.
FIGS. 6 to 9 show another embodiment of the invention.
FIG. 6 shows the arrangement of line image sensors. As shown in the drawing, in this embodiment, a line image sensor 50 is divided into partial sensors 50a, 50b, 50c, 50d, 50e, 50f. The partial sensors 50a, 50b receive the subject light from the detecting region X1 in the photographing image plane 70 shown in FIG. 7. The partial sensors 50c, 50d receive the subject light from the detecting region X2, and the partial sensors 50e, 50f receive the subject light from the detecting region X3. The horizontal focus detecting circuit 22 calculates the defocusing amount and direction on the basis of the output from the partial sensors. The vertical focus detecting circuit 23 calculates the defocusing amount and direction on the basis of the output from the vertical line image sensors 5c, 5d, like the above-described embodiment.
FIG. 8 shows a flow chart for focusing control in this embodiment.
In Step S21, the attitude of the camera is detected according to the states of the mercury switches SW1, SW2 in the same way as the first embodiment. If the camera is in the horizontal attitude (shown by (1) or (4) in FIG. 4), the horizontal focus detecting circuit 22 is started so as to determine the defocusing amount and direction on the basis of the output from the central partial sensors 50c, 50d (corresponding to the detecting region X2). Namely, the detecting circuit 22 detects the focus. In Step S22, a decision is made on the basis of the output from the partial sensors 50c, 50d as to whether or not the focus can be detected. If it is decided that the focus cannot be detected, the focus is detected on the basis of the output from the vertical line image sensors 5c, 5d (corresponding to the detecting region Y). If it is decided in Step S23 that the focus cannot be detected, the impossibility of focusing is indicated in Step S24 in the same way as that described above.
In the case of Yes in Step S22, the flow moves to Step S25. In the case of Yes in Step S23, the output from the image sensors 5c, 5d is handled as the output from the partial sensors 50c, 50d, and the flow moves to Step S25. In Step S25, the focus is detected on the basis of the output from the partial sensors 50a, 50b (corresponding to the detecting region X1), the partial sensors 50c, 50d (corresponding to the detecting region X2 or Y) and the partial sensors 50e, 50f (corresponding to the detecting region X3). The detection may be controlled by, for example, the method disclosed in Japanese Patent Application Laid-open No. 63-18314. The details of this control method are not described below because the method per se is not part of the present invention. The processing then goes to Step S27 in which the photographic lens 1 is focused on the basis of the results of focus detection performed in Step S25.
On the other hand, if it is decided in Step S21 that the camera is in the vertical attitude, i.e., the attitude shown by (2) or (3) in FIG. 4, the focus is detected on the basis of the output from the vertical line image sensors 5c, 5d. If it is decided in Step S28 that the focus cannot be detected, the focus is detected on the basis of the output from the partial sensors 50c, 50d, and the flow moves to Step S29. If it is decided in Step S29 that the focus cannot be detected, the impossibility of focusing is indicated in Step S30, and the processing is finished. If it is decided in Step S29 that the focus can be detected, the output from the partial sensors 50c, 50d is handled as the output from the vertical line image sensors 5c, 5d in Step S31, and the flow then moves to Step S32.
If it is decided in Step S28 that the focus can be detected, a decision is made in Step S33 as to whether or not the focus can be detected with the uppermost partial sensors. When the camera is in the attitude (2), the uppermost partial sensors are the partial sensors 50a, 50b (corresponding to the uppermost detecting region X1). When the camera is in the attitude (3), the uppermost partial sensors are the partial sensors 50e, 50f (corresponding to the uppermost detecting region X3). In the case of No in Step S33, the focus detecting output (defocusing amount and direction) based on the output from the vertical line image sensors 5c, 5d is used in Step S34. The flow then moves to Step S27 for focusing on the basis of that output.
In the case of Yes in Step S33, the flow moves to Step S32 for determining the difference ΔD (ΔD=|Dy-Dup|) between the focus detecting output Dy based on the output from the vertical line image sensors 5c, 5d and the focus detecting output Dup from the uppermost partial sensors. If the difference ΔD is less than a predetermined value DO, the focus detecting output based on the output from the uppermost partial sensors is employed in Step S35. If the difference ΔD is over the predetermined value DO, the focus detecting output based on the output from the vertical line image sensors 5c, 5d (in this case, extended in the horizontal direction of the subject) is employed in Step S36, and the flow then moves to Step S27.
In the detection of the focus according to the above-described procedure, priority is given to the horizontal line image sensor 50 when the camera is in the horizontal attitude, and priority is given to the vertical line image sensors 5c, 5d when the camera is in the vertical attitude in the same way as in the first embodiment. The same effects as those obtained in the first embodiment can thus be obtained. Particularly, in this embodiment, when the camera is in the vertical attitude, i.e., the attitude in which the horizontal focus detecting regions X1, X2, X3 are vertically extended, the vertical line image sensors 5c, 5d and the uppermost partial sensors have priority for detecting the focus.
When a person is photographed, for example, by the camera in the vertical attitude, as shown in FIG. 9, the uppermost detecting region (X1 in the case shown in FIG. 9) of the horizontal detecting regions X1, X2, X3 is frequently placed at the position of the face of the subject. The photographic lens can thus be focused on the face of the subject by the uppermost partial sensors given priority. However, when two persons form a line, the uppermost detecting region is placed in the background, and there is thus the possibility of producing a so-called middle blank. The difference ΔD between the focus detecting output Dup based of the output from the uppermost partial sensors and the focus detecting output Dy based on the output from the vertical line image sensors 5c, 5d is thus determined. When the difference ΔD is less than the predetermined value DO, it is decided that the main subject is placed in the uppermost detecting region, and the focus detecting output based on the output from the uppermost partial sensors is employed. When the difference ΔD is greater than the predetermined value DO, it is decided that the main subject is not placed in the uppermost detecting region, and the focus detecting output based on the output from the vertical line image sensors 5c, 5d is employed for driving the lens. It is therefore possible to surely focus on the main subject.
Although, in this embodiment, the horizontal line image sensor is divided into a plurality portions, the vertical line image sensor may be divided. Also, while the above embodiments concern the case in which the focus is detected on the basis of the subject light passed through the photographic lens, the focus may be detected by receiving the subject light without passing through the photographic lens. In addition, the horizontal and vertical focus detecting regions need not be arranged in a cross form, but may be separated from each other. Further, although the above embodiments concern the case where priority is given to the line image sensors corresponding to the focus detecting region extended in the horizontal direction of the subject, priority may be given to the line image sensors corresponding to the focus detecting region extended in the vertical direction of the subject. Of course, attitude detecting devices for the camera are not limited to the mercury switches SW1, SW2.
In the present invention, in a camera having horizontal and vertical focus detecting photoelectric conversion elements, the direction of the photoelectric conversion elements given priority, i.e., the detecting region given priority, with respect to the subject remains unchanged regardless of the attitude of the camera. It is thus possible to effect focusing of the photographic lens without undue delay even if the attitude with respect to the subject is changed. | An autofocus camera conducts a focus detection operation with one of differently directed sets of photoelectric conversion elements which is given priority according to the detected attitude of the camera. If focusing cannot be effected using the elements given priority, a focus detection operation is automatically conducted with the other elements. Also provided is a camera having a first mode of operation in which focusing detecting operations are conducted which collectively utilize outputs of all of the elements of differently directed sets of photoelectric conversion elements when a first camera attitude is detected, and a second mode of operation in which focusing detecting operations are conducted which collectively disregard the output of at least one conversion element when a second camera attitude is detected. | 24,150 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a national phase entry under 35 U.S.C. §371 of International Application No. PCT/CN2014/090535 filed Nov. 7, 2014 which claims priority from Chinese application 201410029070.X filed Jan. 22, 2014, all of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to a sensing control system. More specifically, it is a sensing control system for an electric toy.
BACKGROUND
Regarding the currently available electric toys, one type of them is controlled by a mechanical switch or button. Through turning on a mechanical switch or button provided on the body of an electric toy, the toy accordingly makes certain corresponding actions, which is driven by electric power. Nevertheless, the action of this type of electric toys cannot be controlled by a user. That is to say, after the mechanical switch or button being turned on, the electric driving device of the toy can only operate based on the parameters set in the production; in other words, these parameters are fixed and thus cannot be changed or modified. As a result, the action of the toy cannot be changed. In addition, there is another type of electric toy that can be controlled with a remote control. Through the remote control, the electric toy's action can be controlled. That is to say, by virtue of a remote control, a user can change or modify the action parameters of the toy, which leads to corresponding changes of the toy's action. However, this type of toy is significantly dependent on its remote control. In the case that its remote control is damaged, the toy would no longer function. Further, it could be a challenge for a child at very young age to control an electric toy's action through a remote control. Moreover, there is another type of electric toys that can be control through its sensing function, such as the non-contact sensing, for example, infrared sensing, and the contact sensing, for example, slot card sensing. Nevertheless, as for the currently available sensing controlled operation, their functions are actually equivalent to that of the above mentioned switch or button. That is to say, upon receiving a sensing signal, the toy can only make one corresponding action. As a result, this type of toy is not able to accomplish action changes through those sensing controls as well.
SUMMARY OF DISCLOSURE
To address the technical problem in the existing technology described above, one aim of the present invention is to provide a sensing control system for an electric toy, which is able to control the toy's action change by virtue of the number of frequency or sensing signals.
In order to achieve the foregoing aim, the present invention employs the technical solution as follows: a sensing control system for an electric toy, characterized by comprising:
a signal detection module for receiving an external sensing and then generating a sensing signal;
a calculation and control module for receiving the sensing signal and counting a number of the sensing signal and then sending out different control signals corresponding to different numbers of the sensing signals; and
an electric driving module for receiving the control signal, and then sending a driving signal to the electric toy, so as to control the electric toy to work.
In which, the signal detection module comprises a non-contact sensing circuit, the non-contact sensing circuit is provided with a sensing receiver, the sensing receiver tracks and senses an action of a user in a real time manner, with respect to each action made by the user, the sensing receiver outputs one sensing signal and sends out the sensing signal to the calculation and control module.
In the present invention, the non-contact sensing circuit is selected from the group consisting of photo-sensitive sensing circuit, magnetic sensing circuit, thermal sensing circuit and sound sensing circuit.
In addition, in order to count the number or frequency of the sensing event, the calculation and control module comprises a control chip, the control chip is able to record the number of sensing signal sent out from the signal detection module in a continuous time period, and according to the recorded number of sensing signal to further send out a control signal to the electric driving module, wherein the control signal is corresponding to the recorded number of sensing signal.
Moreover, in order to identify the number of sensing and accordingly send out a corresponding control signal, the control chip has been stored with a plurality sets of control signals, wherein each set of control signal is corresponding to a range of the number, in the case that the above mentioned recorded number is not within any one of the ranges of the number, no signal is sent out; while in the case that the recorded number is within one of the ranges of the number, send out the control signal that is corresponding to the range of the number within which the recorded number is.
The sensing control system of the present invention can be applied in a wide variety of different electric toys. In this regard, the disclosed electric driving module can be selected from the group consisting of motor driving module, light driving module, sound driving module, electromagnet driving module and a combination of two or more of the foregoing.
More specifically, in the case the electric driving module is a motor driving module comprising a motor and the calculation and control module is provided with a single chip microcomputer (SCM), the single chip microcomputer (SCM) would be stored with the control signals as follows: when a range of the number is N 1 , the motor runs at a speed of S 1 for T 1 seconds; when a range of the number is N 2 , the motor runs at a speed of S 2 for T 2 seconds; and when a range of the number is N 3 , the motor runs at a speed of S 3 for T 3 seconds; and so forth, when a range of the number is N m , the motor runs at a speed of S m for T m seconds; when a range of the number is N 2 , in which N 1 <N 2 <N 3 <N m , S 1 <S 2 <S 3 <S m , and T 1 <T 2 <T 3 <T m . On the other hand, the signal detection module is a photo-sensitive sensing module that comprises a phototransistor, the phototransistor is arranged on an upper surface of the electric toy, when a user waves his or her hand above the electric toy, the phototransistor receives a sensing and accordingly sends out a sensing signal to the calculation and control module, in the case that the user waves his or her hand for X times in a continuous time period and with a time interval between two consecutive waving actions no longer than 1 second, 1 second after the termination of the waving action by the user, the single chip microcomputer (SCM) counts the number of the received sensing signal and reaches a counting number X, and then respectively compares this number X with N 1 , N 2 , N 3 . . . N m , if X is smaller than N 1 , no signal is sent out, if X is within one of N 2 , N 3 . . . N m , the control signal corresponding to the range of the number within which X is sent out to the electric driving module, which further drives the motor to run according to the specified running speed and the specified running time corresponding to that control signal.
Furthermore, the signal detection model of the present invention may comprise at least two non-contact sensing circuits, with each of the non-contact sensing circuits having been provided with a sensing receiver, the sensing receiver tracks and senses an action of a user in a real time manner, with respect to each action made by the user, the sensing receiver outputs one sensing signal and sends out this sensing signal to the calculation and control module, and the calculation and control module then sends out a corresponding control signal based on a determination of the combination of received a plurality of sensing signals. On the other hand, the non-contact sensing circuit is selected from the group consisting of photo-sensitive sensing circuit, magnetic sensing circuit, thermal sensing circuit, sound sensing circuit and a combination of two or more of the foregoing.
In the present invention, the sensing control system has been provided with a calculation and control module. Through the calculation and control module, it is able to count the number of sensing events received by the signal detection module. Subsequently, based on the result from a comparison between the number of sensing events obtained from the foregoing counting and the data previously stored in the calculation and control module, a control signal that corresponds to the obtained number of sensing events is further sent out to an electric driving module, and eventually, the electric driving module sends out a driving signal to control the electric toy to act. As a result, based on different number of sensing events, the electric toy is capable of performing different actions or allowing one action to have changes in its speed. In this way, the present invention is able to make an electric toy that has been equipped with the sensing control system disclosed in the present invention to go beyond the limitation of a remote control, and thus becomes suitable as a toy for children of different ages. In addition, it makes a toy gain the advantages of becoming more user friendly, more interactive, more interesting, and thus would become many children's favorite. On the other hand, the sending control system may be provided with at least two non-contact sensing circuits, and each of the non-contact sensing circuits is provided with a sensing receiver. As a result, for each action or movement made by a user, the respective sensing receiver would output a corresponding sensing signal, and send out the foregoing sensing signal to the calculation and control module; and the calculation and control module accordingly sends out a corresponding control signal based on a determination of the received combination of a plurality of sensing signals. In this way, a user can have more different ways to play the electric toy. For example, a user can control the electric toy to move forward and backward, to turn to its left side or right side. In addition, by virtue of different signal combinations, the electric toy can gain more functions, such as prevention of trample and many other new functions, and make the operation become more flexible and easier to control. In addition, as disclosed previously, the non-contact sensing circuits of a toy may be selected from the group consisting of photo-sensitive sensing circuit, magnetic sensing circuit, thermal sensing circuit, sound sensing circuit and a combination of two or more of the foregoing. In this way, different sensing circuits may be employed together to control different functions of the same electric toy. In this way, the operability and enjoyability of the electric toy has been effectively improved.
The present invention will be further described in combination with the accompanying drawings and embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of the circuit of an embodiment of the present invention.
FIG. 2 is a schematic view of the circuit of another embodiment of the present invention.
DETAILED DESCRIPTION OF THE DRAWINGS
As shown in FIG. 1 and FIG. 2 , the present invention is a sensing control system for an electric toy, comprising: a signal detection module for receiving an external sensing and then generating a sensing signal; a calculation and control module for receiving the sensing signal and counting a number of the sensing signal, and then sending out different control signals corresponding to different numbers of the sensing signals; as well as an electric driving module for receiving the control signal and then sending a driving signal to the electric toy, so as to control the electric toy to work. In addition, through the calculation and control module, it is able to count the number of sensing signals received by the signal detection module. Subsequently, based on the result from a comparison between the number of sensing events obtained from the foregoing counting and the data previously stored in the calculation and control module, a control signal that is corresponding to the obtained number of sensing events is further sent out to the electric driving module, and eventually, the electric driving module sends out a driving signal to control the electric toy. As a result, based on different number of sensing events, the electric toy is capable of performing different actions or allowing one action to have changes in its speed. In this way, the present invention is able to make an electric toy that has been equipped with the sensing control system disclosed in the present invention go beyond the limitation of a remote control, and thus becomes suitable as a toy for children of different ages. In addition, it makes a toy gain advantages of becoming more user friendly, more interactive, more interesting, and thus would become many children's favorite.
DETAILED DESCRIPTION
Embodiment 1
As shown in FIG. 1 , in this embodiment, the signal detection module comprises a non-contact sensing circuit, and the non-contact sensing circuit is a photo-sensitive sensing circuit, which corresponds to a sensing receiver that is a phototransistor. In addition, in this embodiment, it is also provided with an emission source. The phototransistor and the emission source have been arranged on the top of an electric toy car, so as to allow them to be able to track and sense the hand waving action of a user in a real time manner. Accordingly, when a user waves his or her hand once above the electric toy car, the sensing receiver correspondingly outputs a sensing signal, and then sends out the sensing signal to the calculation and control module. In addition, the calculation and control module is provided with a single chip microcomputer (SCM). The SN8P2511-SOP8 single chip microcomputer (SCM) has been employed in the present invention. This SCM is able to record the number of the sensing signal sent out from the above mentioned photo-sensitive sensing receiver in a continuous time period, as well as according to the recorded number of sensing signal to send out a control signal that is corresponding to the recorded number of sensing signal to the electric driving module. Moreover, the SCM has been stored of five sets of control signals, wherein each set of control signal is corresponding to a respective range of number. In the case that the recorded number is not within any one of the ranges of number, no signal is sent out; while in the case that the recorded number is within one of the ranges of number, send out the control signal that is corresponding to the range of number within which the recorded number of sensing signal is. Furthermore, the calculation and control module is also provided with an LED light. The LED light is able to flash according to the speed of a user's hand waving action. In this embodiment, the electric driving module is an electric driving module containing a motor, which has been arranged in the electric toy car. The control signal sent out from the SCM is used to control the motor's operation.
The specific control signals stored in the single chip microcomputer (SCM) in this embodiment are as follows: {circumflex over (1)} waving hand 4 to 6 times, 1 second after completion of the foregoing waving action the electric car moving forward for 1 second, and the moving speed being 30% of a full running speed of the motor; {circumflex over (2)} waving hand 7 to 9 times, 1 second after completion of the foregoing waving action the electric car moving forward for 2 seconds, and the moving speed being 45% of a full running speed of the motor; {circumflex over (3)} waving hand 10 to 14 times, 1 second after completion of the foregoing waving action the electric car moving forward for 4 seconds, and the moving speed being 60% of a full running speed of the motor; {circumflex over (4)} waving hand 15 to 20 times, second after completion of the foregoing waving action the electric car moving forward for 8 seconds, and the moving speed being 80% of a full running speed of the motor; and {circumflex over (5)} waving hand more than 21 times, second after completion of the foregoing waving action the electric car moving forward for 12 seconds, and the moving speed being 100% of a full running speed of the motor.
In the case that the sensing control system described in this embodiment is used in an electric toy car, the operation procedure accordingly is as follows: press the power button, the system starts to work and the electric toy car is in a standby state at this moment, when a user waves his or her hand above the electric toy car and the waving action meets the requirement that the time interval between two consecutive hand waving actions is no more than 1 second, if the number of hand waving action is no more than 3 times within a time period of 4 seconds, the electric toy car does not respond and thus remains in the standby state to wait for future sensing; if the number of hand waving action is more than 4 times within a continuous time period, according to the respective control signal from the SCM, the user is able to control the electric toy car to move. For example, in the case that the user waves his or her hand 5 times, 1 second after completion of the foregoing waving action, the electric car moves forward for 1 second at the moving speed that is 30% of a full running speed of the motor; in the case that the user waves his or her hand 10 times, 1 second after completion of the foregoing waving action, the electric car moves forward for 4 seconds at the moving speed that is 60% of a full running speed of the motor; and in another case that the user waves his or her hand 25 times, 1 second after completion of the foregoing waving action, the electric car moves forward for seconds at the moving speed that is 100% of a full running speed of the motor. Further, after finishing one moving forward action, the electric toy car returns to the standby state, and in the case that a hand waving action is sensed within the next 5 minutes, the electric toy car runs again according to the respective number of hand waving actions. On the other hand, if no any hand waving action has been sensed within the next 5 minutes, the electric toy car then goes into an off state. In this case, a user needs to press the power button again to turn on the electric car back into a play state. Moreover, if a user needs to shut down the toy car manually, the user may achieve it by pressing the power button for 2 to 3 seconds.
Embodiment 2
As shown in FIG. 2 , in this embodiment, the signal detection module comprises three non-contact sensing circuits, and each of the three non-contact sensing circuits has been provided of a sensing receiver, wherein two of the three non-contact sensing circuits are photo-sensitive sensing circuits, with their corresponding sensing receivers as phototransistors; and the third non-contact sensing circuit is a magnetic sensing circuit, with its corresponding sensing receiver as a magnetic sensing circuit. In this embodiment, the two phototransistors are able to track and sense the hand waving action from a user in a real time manner. On the other hand, the magnetic sensing element can only sense when a user is making a hand waving action with a magnetic article in his or her hand. When a user waves his or her hand once, the sensing receiver that is capable of sensing will correspondingly output a sensing signal, and then send out the sensing signal to the calculation and control module. The calculation and control module controls the moving direction of the electric toy by means of determining the specific sequence of the generated sensing signals. The calculation and control module has been provided with an SN8P2511-SOP14 single chip microcomputer (SCM). The single chip microcomputer (SCM) is able to record the respective number of sensing signals sent out from the above mentioned three sensing receivers in a continuous time period, as well as according to the recorded number to send out a control signal that is corresponding to the recorded number to the electric driving module. Similarly, the SCM has been stored with multiple sets of control signals, in which each set of control signal is corresponding to a respective range of number. In the case that the recorded number is not within any one of the ranges of the number, no signal is sent out; while in the case that the recorded number is within one of the ranges of the number, send out the control signal that corresponds to the range of the number within which the recorded number is. And similarly, the calculation and control module is also provided with an LED light. The LED light is able to flash according to the speed of a user's hand waving action. In this embodiment, the electric driving module is an electric driving module containing a motor, which has been arranged in the electric toy car. The control signal sent out from the SCM is used to control the motor's operation.
In this embodiment, the above mentioned two phototransistors are disposed on the top of an electric toy car and in a front to rear arrangement. The magnetic element is disposed on one side of the two phototransistors. When a user makes a hand waving action from rear side toward front side of the electric toy car with an empty hand, the phototransistor located on the rear side of the toy car senses the waving action first and accordingly sends out a sensing signal, and then the phototransistor located on the front side of the toy car senses the waving action next and accordingly sends out a sensing signal as well. As for the magnetic element, it is not able to sense the waving action with an empty hand and accordingly does not send out any magnetic sensing signal in this situation. The SCM first determines the sequence in which the two sensing signals have been generated as well as the number of the waving actions made by the user in a continuous time period, and accordingly, controls the electric toy car to move forward at a speed corresponding to the number of sensed waving actions. In the case when a user makes a hand waving action from front side toward rear side of the electric toy car with an empty hand, the phototransistor located on the front side of the toy car senses the waving action first and accordingly sends out a sensing signal, and then the phototransistor located on the rear side of the toy car senses the waving action next and accordingly sends out a sensing signal as well. As for the magnetic element, it is not able to sense the waving action with an empty hand and accordingly does not send out any magnetic sensing signal. The SCM first determines the sequence in which the two sensing signals have been generated as well as the number of the waving actions made by the user in a continuous time period, and accordingly, controls the electric toy car to move backward at a speed corresponding to the number of sensed waving actions. In another case, when a user makes a hand waving action above the electric toy car with a magnetic article in hand, the two phototransistors sensing the hand waving action sequentially and accordingly send out respective sensing signals, in addition, because of the magnetic article, the magnetic sensing element will send out a magnetic signal in this case. The SCM first determines the sequence in which the two sensing signals have been generated as well as the number of the waving actions made by the user in a continuous time period, and accordingly, controls the electric toy car to move forward or backward at a speed corresponding to the number of hand waving actions. And at the same time, the SCM receives the magnetic sensing signal sent form the magnetic sensing circuit and accordingly sends out a corresponding instruction to control certain other functions of the electric toy car. More specifically, in this embodiment, when the SCM receives the magnetic sensing signal, it will further control to increase running speed of the motor in the electric toy car. That is to say, with the same number of hand waving actions, when a user makes the hand waving actions with a magnetic article in the user' hand, the electric toy car would move faster than that when the user makes hand waving actions with an empty hand.
Although the present invention has been described in reference to the specific embodiments described above, the description of embodiments does not intend to limit the present invention. On the basis of the description of the present invention, a person of ordinary skill in the art is able to anticipate other changes for the disclosed embodiments. Therefore, these changes are within the scope defined by the claims of the present application. | The present invention provides a sensing control system for an electric toy, characterized in that it comprises a signal detection module for receiving an external sensing and then generating a sensing signal; a calculation and control module for receiving the sensing signal and counting a number of the sensing signal, and then sending out different control signals corresponding to different numbers of the sensing signals; and an electric driving module for receiving the control signal and then sending a driving signal to the electric toy, so as to control the electric toy to work. Therefore, according to different numbers of sensing signals, the electric toy is able to perform different actions or speed changes of the same action. In this way, the toy equipped with the sensing control system of the present invention can go beyond the limitation of a remote control, and thus becomes suitable as a toy for children of different ages. In addition, it makes a toy gain advantages of becoming more user friendly, more interactive, more interesting, and thus would become many children's favorite. | 25,340 |
STATEMENT OF GOVERNMENT RIGHTS
[0001] This invention was made with Government support under Contract No.: N00014-12-C-0472 awarded by the Office of Navy Research. The Government has certain rights in this invention.
BACKGROUND
[0002] The present application relates to reactive material stacks, and more particularly to reactive material stacks with tunable ignition temperatures.
[0003] Reactive materials are a class of materials which can react to generate heat through a spontaneously exothermic reaction without producing gaseous products or generating a large pressure wave. Reactive materials are thus useful in a wide variety of applications requiring generation of intense, controlled amount of heat, including bonding, melting and microelectronics where the release of energy needed can be triggered by external ignition with, or without, a source of oxygen. For certain applications, it may be important that the energy stored in the reactive materials is not released until needed. For example and when employed as erasure elements to induce phase transformation of phase change materials of phase change memory (PCM) cells in an integrated circuit chip, the reactive materials need to be benign during the back end-of-line fabrication process (which typically requires annealing the chip at a temperature up to 400° C.) and normal chip operations, but can be ignited quickly when a triggering event occurs, e.g., when the chip is compromised (e.g., lost or stolen) and a possibility of a security breach could occur.
SUMMARY
[0004] The present application provides reactive material stacks with tunable ignition temperatures. By separating alternating layers of reactive materials from one another with a barrier layer, the interdiffusion of metal elements of the reactive materials is prevented. The reactive material stacks thus remain unreacted until a high energy threshold is reached.
[0005] In one aspect of the present application, a reactive material stack is provided. The reactive material stack includes alternating layers of a first reactive material and a second reactive material and a barrier layer located between the layers of the first reactive material and the second reactive material, wherein the barrier layer comprises a transition metal, an oxide thereof, a nitride thereof, aluminum oxide (Al x O y ) or a combination thereof.
[0006] In another aspect of the present application, a method of forming a reactive material stack is provided.
[0007] In one embodiment, the method includes forming a layer of a first reactive material over a substrate, forming a barrier layer over the layer of the first reactive material, forming a layer of a second reactive material over the barrier layer, forming another barrier layer over the layer of the second reactive material and repeating the forming of the layer of the first reactive material, the forming of the barrier layer, the forming of the second reactive material, and the forming of the another barrier layer to provide a desired thickness for the reactive material stack.
[0008] In another embodiment, the method includes forming a layer of a first reactive material over a substrate, forming a layer of a second reactive material over the layer of the first reactive material, forming a barrier layer over the layer of the second reactive material, and repeating the forming of the layer of the first reactive material, the forming of the second reactive material, and the forming of the barrier layer to provide a desired thickness for the reactive material stack.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
[0009] FIG. 1 is a cross-sectional view of an exemplary reactive material stack that can be employed in an embodiment of the present application.
[0010] FIG. 2 is a cross-sectional view illustrating a barrier layer stack that can be employed in the exemplary reactive material stack of the present application.
[0011] FIG. 3 is a cross-sectional view of another exemplary reactive material stack that can be employed in another embodiment of the present application.
[0012] FIG. 4A shows a graph of sheet resistance versus temperature for a conventional reactive material stack including a bilayer of Al/Ni formed over a SiO 2 coated substrate.
[0013] FIG. 4B shows a X-ray diffraction (XRD) profile of the conventional reactive material stack.
[0014] FIG. 5A shows a graph of sheet resistance versus temperature for a first exemplary reactive material stack that includes a single barrier layer sandwiched between an Al layer and a Ni layer according to a first example of the present application.
[0015] FIG. 5B shows a XRD profile of the first exemplary reactive material stack.
[0016] FIG. 6A shows a graph of sheet resistance versus temperature for a second exemplary reactive material stack that includes a barrier layer stack sandwiched between an Al layer and a Ni layer according to a second example of the present application.
[0017] FIG. 6B shows a XRD profile of the second exemplary reactive material stack.
[0018] FIG. 6C shows a graph of sheet resistance versus heating time for the second exemplary reactive material stack.
[0019] FIG. 7 is a bar graph showing effects of barriers layers on ignition temperatures of a Ni—Al reactive material pair.
DETAILED DESCRIPTION
[0020] The present application will now be described in greater detail by referring to the following discussion and drawings that accompany the present application. It is noted that the drawings of the present application are provided for illustrative purposes only and, as such, the drawings are not drawn to scale. It is also noted that like and corresponding elements are referred to by like reference numerals.
[0021] In the following description, numerous specific details are set forth, such as particular structures, components, materials, dimensions, processing steps and techniques, in order to provide an understanding of the various embodiments of the present application. However, it will be appreciated by one of ordinary skill in the art that the various embodiments of the present application may be practiced without these specific details. In other instances, well-known structures or processing steps have not been described in detail in order to avoid obscuring the present application.
[0022] Referring to FIG. 1 , there is illustrated a reactive material stack 8 that can be employed in an embodiment of the present application. The reactive material stack 8 includes alternating layers of a first reactive material 10 and a second reactive material 20 , and a barrier layer 30 sandwiched between each layer of the first reactive material 10 and the second reactive material 20 . The reactive material stack 8 typically contains tens to about one hundred of these layers and has a total thickness from 0.5 μm to 10 μm, although greater or lesser thicknesses may be contemplated.
[0023] The reactive material stack 8 can be formed over a substrate (not shown). The substrate can be a semiconductor substrate, a dielectric substrate, a conductive material substrate, or a combination thereof. In one embodiment, the substrate can include a bulk semiconductor substrate, a semiconductor-on-insulator (SOI) substrate or a III-V semiconductor substrate as known in the art. The substrate may also include metal lines and/or metal via structures embedded within at least one dielectric material layer.
[0024] The first reactive material and the second reactive material are selected to react with one another in an exothermic reaction upon ignition. In one embodiment, such exothermic reaction produces sufficient heat to cause the alteration to the memory state of phase change memory (PCM) cells in integrated circuits. Exemplary sets of the first reactive material and second reactive material include, but are not limited to, Ni/Al, Al/Pd, Cu/Pd, Nb/Si and Ti/Al. Additional exemplary sets of the first and second reactive materials that may be used in embodiments of the present application are described in “A Survey of Combustible Metals, Thermites, and Intermetallics for Pyrotechnic Applications”, by Fischer et al., 32nd AIAA/ASME/SAE/ASEE Joint Propulsion Conference, Lake Buena Vista, Fla., 1996, the disclosure of which is hereby incorporated by reference in its entirety.
[0025] The reaction of the first and second reactive materials may be ignited by a mechanical stress, an electric spark, a laser pulse, or other similar energy ignition sources. Upon ignition, metal elements of the first reactive material and second reactive material intermix due to atomic diffusion to form an alloy, intermetallic or a composite of the first reactive material and the second reactive material. The change in chemical bonding, caused by interdiffusion and compound formation, generates heat in an exothermic chemical reaction.
[0026] The layers of the first and second reactive materials 10 , 20 may be formed using conventional film deposition techniques such as, for example, physical vapor deposition (PVD) or chemical vapor deposition (CVD), atomic layer deposition (ALD), electroplating and spin-on (sol-gel) processing. The thickness of each layer of the first reactive material 10 and the second reactive material 20 may range from 1 nm to 200 nm, although lesser or greater thicknesses can also be employed. The thickness of the layers may be a constant or some layers may have a different thickness than others.
[0027] Each barrier layer 30 acts as a diffusion barrier to reduce interdiffusion of the first and second reactive materials, thus preventing the reactions from taking place until a triggering event designated to initiate the reaction occurs. Each barrier layer 30 may include transition metals selected from Group IVB or VB of the Period Table of Elements, oxides of these transition meals, nitrides of these transition meals, aluminum oxide (Al x O y with x from 1 to 2 and y from 1 to 3) or combinations thereof. Exemplary transition metals include, but are not limited to, Ti, Zr, Hf, V, Nb and Ta. Each barrier layer 30 may be formed of a single layer structure or a multilayer stack (as shown in FIG. 2 ). In one embodiment, each barrier layer 30 includes a single layer of Ta. In another embodiment, each barrier layer 30 includes a stack selected from the group consisting of Ta/Ta x O y , Al x O y /Ta/Ta x O y or Al x O y /Ta/Ta x O y /Ta/Ta x O y . For example and as shown in FIG. 2 , each barrier layer 30 includes a five-layer stack of Al x O y (labeled as 32 in the drawing) and alternating layers of Ta (labeled as 34 in the drawing) and Ta x O y (labeled as 36 in the drawing) with x from 1 to 3 and y from 1 to 5. It should be noted that the number of alternating layers in the barrier layer stack is not limited to four layers as shown in FIG. 2 , other numbers of alternating layers can also be employed in the barrier layer stack. The thickness of each barrier layer 30 may be from 1 nm to 20 nm, although lesser and greater thicknesses can also be employed.
[0028] The barrier layers 30 may be formed, for example, by PVD, CVD, ALD, electroplating or spin-on (sol-gel) processing. In one embodiment and when transition metal oxides or metal nitrides are employed in the barrier layer 30 , the transition metal oxide layer or the transition metal nitride layer may be formed by first forming a transition metal layer and converting a surface portion of the transition metal layer by thermal nitridation and/or thermal oxidation.
[0029] Referring to FIG. 3 , there is illustrated another reactive material stack 8 ′ that can be employed in another embodiment of the present application. The reactive material stack 8 ′ includes alternating layers of a first reactive material 10 and a second reactive material 20 , and a barrier layer 30 sandwiched between each pair of the layer of the first reactive material 10 and the layer of the second reactive material 20 . Each layer is composed of the same material and can be formed by the same method as described above in FIG. 1 .
[0030] The energy required to initiate the exothermic reaction is directly related to the physical properties, e.g., thickness and the composition of each barrier layer 30 . To illustrate the effects of the barrier layer 30 on the ignition temperatures of the reactive material stack 8 of the present application, a barrier layer or a barrier layer stack of the present application is introduced between an Al layer and a Ni layer. In a first example and when a single barrier layer is employed, a first exemplary reactive material stack of the present application includes, from bottom to top, 20 nm Al/10 nm Ta/10 nm Ni formed over a SiO 2 coated Si substrate. In a second example and when a barrier layer stack is employed, a second exemplary reactive material stack includes, from bottom to top, 20 nm Al/Al x O y /5 nm Ta/Ta x O y /5 nm Ta/Ta x O y /10 nm Ni formed over a SiO 2 coated Si substrate. The oxide layers in the second example were formed by exposing the structure to an air break after deposition of each metal layer. The ignition temperatures obtained from the first and second exemplary reactive material stacks are compared with a conventional reactive material stack composed a bilayer of 20 nm Al and 10 nm Ni formed over a SiO 2 coated Si substrate.
[0031] FIG. 4A shows a sheet resistance of the conventional reactive material stack as a function of temperature and FIG. 4B shows a X-ray diffraction (XRD) profile of the conventional reactive material stack as a function of temperature at a heating rate of 3° C./s in a helium ambient. As shown in FIG. 4A , the sheet resistance initially increases linearly with increasing of temperature but deviates from linearity at about 260° C., indicating that at about 260° C. the reaction between Al and Ni proceeds to form an Al 3 Ni 2 alloy. The phase change at about 260° C. is also evidenced in the XRD profile. As shown in FIG. 4B , phases of Al and Ni disappear while a new Al 3 Ni 2 phase appears after heating to 260° C. Thus, both sheet resistance and XRD measurements indicate that a temperature of 260° C. at a ramp rate of 3° C./scan trigger the reaction of Al and Ni.
[0032] FIG. 5A shows a sheet resistance of the first exemplary reactive material stack of the present application as a function of temperature and FIG. 5B shows a XRD profile of the first exemplary reactive material stack as a function of temperature at a heating rate of 3° C./s in a helium ambient. As shown in FIG. 5A , the sheet resistance initially increases linearly with increasing of temperature but deviates from linearity at about 400° C., indicating that at about 400° C. the reaction between Al and Ni proceeds to form an Al 3 Ni 2 alloy. The phase change at 400° C. is also evidenced in the XRD profile. As shown in FIG. 5B , phases of Al and Ni disappear while a new Al 3 Ni 2 phase appears after heating to 400° C. This means that a reaction temperature of 260° C. is not sufficient to trigger the reaction of Al and Ni when a Ta barrier layer is present therebetween, but rather a temperature above 400° C. is needed. Thus, by introducing a 10 nm Ta barrier layer between the Al layer and Ni layer, the reaction temperature for Al and Ni couples can be increased to 400° C.
[0033] FIG. 6A shows a sheet resistance of the second exemplary reactive material stack of the present application as a function of temperature and FIG. 6B shows a XRD profile of the second exemplary reactive material stack as a function of temperature at a heating rate of 3° C./s in a helium ambient. As shown in FIG. 6A , the sheet resistance initially increases linearly with increasing of temperature, but deviates from linearity at about 571° C., indicating that at about 571° C. the reaction between Al and Ni proceeds to form an Al 3 Ni 2 alloy. The phase change is also evidenced in the XRD profile. As shown in FIG. 6B , phases of Al and Ni remains at a temperature around 571° C. Thus, by introducing a barrier layer stack between the Al layer and Ni layer, the reaction temperature for Al and Ni couples can be increased to 571° C.
[0034] FIG. 6C shows an sheet resistance of the second exemplary reactive material stack as a function of heating time when the second exemplary reactive material stack is held isothermally at 400° C. for 4 h. As shown in FIG. 6C , there is no increase in sheet resistance as time passes, indicating that the reaction between Al and Ni does not occur at 400° C.
[0035] FIG. 7 is a graph summarizing ignition temperatures of reactive material stacks employing various barrier layers of the present application. Each reactive material stack has a structure represent by 10 nm Ni/X/20 nm Al/SiO 2 , and X represents a barrier layer of the present application. As shown in FIG. 7 , by varying the composition and thickness of the barrier layers, the reaction temperature of the reactive material stacks including Al and Ni reactive material pairs can be tailored to be from 260° C. to 571° C.
[0036] In the present application, by introducing a barrier layer between layers of the first reactive material and second reactive material, the ignition temperature of resulting reactive material stacks can tuned. The reactive material stacks thus formed are benign during the chip fabrication and chip operation, but can be ignited when a triggering event occurs at a desired time. Further, by varying composition and thickness of the barrier layer of the present application, the ignition temperatures of the reactive material stacks can be tuned. The design flexibility can be greatly improved.
[0037] While the application has been described in terms of specific embodiments, it is evident in view of the foregoing description that numerous alternatives, modifications and variations will be apparent to those skilled in the art. Each of the embodiments described herein can be implemented individually or in combination with any other embodiment unless expressly stated otherwise or clearly incompatible. Accordingly, the application is intended to encompass all such alternatives, modifications and variations which fall within the scope and spirit of the application and the following claims. | A reactive material stack with tunable ignition temperatures is provided by inserting a barrier layer between layers of reactive materials. The barrier layer prevents the interdiffusion of the reactive materials, thus a reaction between reactive materials only occurs at an elevated ignition temperature when a certain energy threshold is reached. | 18,913 |
[0001] The present invention relates to ventilatory assist devices and more particularly to a lightweight emergency ventilatory assist device that can be retrofitted onto a conventional protective mask without removing the mask, for example, to provide CPAP in situ, i.e. without having to transport the patient to a medical facility.
BACKGROUND OF THE INVENTION
[0002] The ability to immediately treat respiratory distress substantially reduces the number of fatalities sustained during military operations. Civilian emergency medical technologists stress the concept of the “golden hour.” This interval represents the average time that elapses before a patient with serious or multiple injuries will begin to deteriorate rapidly. Without the ability to deliver on-scene medical support, casualties must be transported to a medical facility for treatment. This is often impossible during active operations.
[0003] Treatment of these casualties in a nuclear-biological-chemical (NBC) environment is even more difficult. Casualties that occur in an NBC environment that require breathing assistance must be performed with extreme caution so as not to contaminate the casualty or the rescuer. When treating a casualty exposed to a nerve agent, it has been proposed that a cricothyroidotomy is the most practical means of providing an airway for assisted ventilation using a hand-powered ventilator equipped with an NBC filter. As part of that proposed practice, when the casualty reaches a medical treatment facility (MTF) where oxygen and a positive pressure ventilator are available, the hand-powered ventilator and NBC filter are employed continuously until adequate spontaneous respiration is resumed.
[0004] Performing a cricothyroidotomy in the field may be difficult during ongoing operations. A method to provide ventilation assistance to a casualty through an existing protective mask may save time and prevent further casualties.
[0005] Another situation facing today's Army is a chemical attack on a large group without protective masks in place. This situation may require the ventilation of hundreds of individuals making the large-scale availability of small lightweight, automatic ventilators useful.
[0006] While there are several ventilators designed for far-forward medical care, for various reasons these ventilators fall short of what is ideal for first response in the operational environment. For example, some are too heavy to be carried on foot. Some require an external source of pressurized gas or power.
[0007] A non-invasive positive pressure respiratory assist device that could be retrofitted onto a protective mask by the patient or another individual without medical training would provide optimize the resources that are available to attend to casualties in military, civil defense, firefighting and settings of an industrial nature.
SUMMARY OF THE INVENTION
[0008] In one aspect, the invention is directed to a mask interface device for a protective mask of the type having a mask filter and a mask expiratory port, the mask expiratory port having an expiratory port valve of the type that is normally closed and openable upon expiration, the mask filter having an inspiratory air inlet, the mask interface device comprising: a mask interface assembly mountable to the mask and having a mounting interface for mounting an air pressure generator in fluid communication with the inspiratory inlet of the mask filter; and an expiratory port interface assembly mountable to the mask expiratory port and comprising at least one opening for venting expired gas to atmosphere and a one-way valve that is positioned to control the flow of expired gas out through the at least one opening, and wherein the one-way valve is set to an opening pressure that provides positive end expiratory pressure or PEEP. Optionally, this opening pressure is between 2.5 and 20 cm H 2 O. Optionally, the mask interface device interfaces directly with the mask filter. In one embodiment of the invention, this interface does not require the filter to have a mating connection and is therefore is universal for a broad class of filters, for example cylindrical filters that project from the mask. Such a cylindrical filter may be of known dimension and other characteristics that may serve as a standard to which a mask interface assembly may be designed. For the sake of convenience, filters serving as a basis for design of the mask interface assembly may be referred to herein as universal filters.
[0009] The invention is also directed to a kit comprising a mask interface assembly and an expiratory port interface assembly. Optionally the kit includes a case sized to include both the mask interface assembly and an expiratory port interface assembly. Optionally the case comprises a belt clip. Optionally the mask interface device comprises an air-pressure measuring device. Optionally, the mask interface device or kit comprises an air pressure generator.
[0010] In another aspect, the invention is directed to a mask interface device for a protective mask of the type having a mask expiratory port, the mask expiratory port having an expiratory port valve of the type that is normally closed and openable upon expiration at an expiratory port valve opening pressure, the mask interface device comprising an expiratory port interface assembly mountable to the mask expiratory port and comprising at least one opening for venting expired gas to atmosphere and a one-way valve that is positioned to control the flow of expired gas out through the at least one opening, and wherein the way valve is set to an opening pressure that provides positive end expiratory pressure or PEEP. Preferably, the opening pressure of the one-way valve is set or settable to a value greater than the expiratory port valve opening pressure. Preferably, the opening pressure of the one-way valve is set or settable to a value that is less than the intra-mask pressure generated by an air pressure generator. Optionally, the mask interface device comprises or is fluidically connectable to an air-pressure measuring device. The air-pressure measuring device may alternatively be configured to sealably mate with the drinking port of the protective mask. Optionally, the mask interface device includes a pressure-relaying interface associated with an air-pressure measuring device, for example air sampling port that is positioned to enable the pressure of gas exiting the expiratory port valve to be measured. The invention is also directed to a kit comprising a mask interface device the mask interface device comprising an expiratory port interface assembly mountable to the mask expiratory port and comprising at least one opening for venting expired gas to atmosphere and a one-way valve that is positioned to control the flow of expired gas out through the at least one opening, and wherein the way valve that is set to an opening pressure that provides positive end expiratory pressure or PEEP. Optionally the kit comprises an air-pressure measuring device. Optionally, the kit further includes a mask interface assembly as define above. Optionally, this mask interface assembly comprises an air pressure generator that is set or settable to control the intra-mask pressure in response to pressure measured by the air-pressure measuring device.
[0011] In another aspect, the invention is directed to a mask interface device for a protective mask of the type having a mask expiratory port, the mask expiratory port having an expiratory port valve of the type that is normally closed and openable upon expiration at an opening pressure that provides positive end expiratory pressure, the mask interface device comprising an expiratory port interface assembly mountable to the mask expiratory port and comprising at least one opening for venting expired gas to atmosphere, a one-way valve that is positioned to control the flow of expired gas out through the at least one opening, and an air-pressure measuring device or a pressure-relaying interface (that is associated with an air pressure measuring device, for example air sampling port), that is positioned to measure the pressure of gas exiting the expiratory port valve, and wherein the one-way valve that is set to open at an opening pressure that is greater than the expiratory port valve opening pressure. Preferably, the opening pressure of the one-way valve is set or settable to a value that is less than the intra-mask pressure generated by an air pressure generator. The invention is also directed to a kit comprising the latter mask interface device. The term “air pressure measuring device” may be used for convenience to refer a port or other interface for such a device, and is not meant to imply that the device is physically located in or outside the expiratory port valve so as long as it is operatively associated with the valve to measure pressure of gas exiting the valve. The foregoing notwithstanding that the disclosure may in other instances explicitly refer to the device as being operatively associated with the valve.
[0012] In one aspect, the invention is directed to a mask interface device for a protective mask of the type having a mask filter and a mask expiratory port, the mask expiratory port having an expiratory port valve of the type that is normally closed and openable upon expiration, the mask filter having an inspiratory air inlet, the mask interface device comprising an air pressure generating assembly having a an air pressure generator in fluid communication with the inspiratory inlet of the mask filter and an expiratory port interface assembly mountable to the mask expiratory port and comprising at least one opening for venting expired gas to atmosphere, one-way valve that is positioned to control the flow of expired gas out through the at least one opening and an air-pressure measuring device or a pressure-relaying interface (that is associated with an air pressure measuring device, for example air sampling port), that is positioned to enable the pressure of gas exiting the expiratory port valve to be measured, and wherein the way valve that is set to open at an opening pressure that is equal to or greater than the expiratory port valve opening pressure. Optionally, the aforesaid device further comprises a controller for controlling the output pressure of the air-pressure generating device in response to pressure measured by the air-pressure measuring device.
[0013] A variety of technologies for measuring pressure are well known to those skilled in the art including pressure transducers and sensors having an air sampling port.
[0014] Optionally, the air pressure generator optionally included within the aforementioned mask interface devices or kits are electrically powered and the mask interface device or kit comprises a controller connectable to the pressure sensor to receive pressure measurement output and operatively connectable to the air pressure generator to achieve a selected mask air pressure in response to output of the pressure sensor. Optionally the air pressure generator is a blower powered by a motor and the controller controls the motor speed. Optionally, the blower is a radial blower having a low rotational mass for power efficiency. Optionally the expiratory port interface device is operatively connected to a one-way valve that is set to an opening pressure that provides positive end expiratory pressure or PEEP. Optionally this valve is a mechanical valve that opens at more than one selected pressure. Optionally this valve is microprocessor controllable to achieve a variety of opening pressures. Optionally the motor controller is set to maintain a mask pressure that equals or exceeds the opening pressure of this valve at any given time. Optionally, the expiratory port interface assembly is mountable to the mask to create a chamber at least partially defined by the said mask expiratory port valve and the one-way valve and wherein said chamber is fluidly connected with the pressure sensor. Optionally, the air pressure generator assembly is secured to the mask filter with a rollable resilient sleeve. Optionally, the rollable resilient sleeve includes a lip portion at one end upon which the sleeve may be rolled. Optionally, the sleeve is capable of being annularly mounted on a receptacle portion of the assembly, the receptacle portion of the assembly having a mouth portion for receiving the filter. Further aspects and embodiments of the invention pertaining to the sleeve will be discussed below.
[0015] According to another aspect of the invention, the invention is directed to a mask interface device comprising:
[0016] a filter receptacle, the filter receptacle having a mouth portion for receiving a filter;
[0017] a rollable sleeve of elastic material; and
[0018] a coupling interface for a respiratory device, the coupling interface defining an aperture to establish a fluidic communication between the respiratory device and the cylindrical filter and adapted to position the respiratory device in fluid communication with the filter. In one embodiment, the mask is a protective mask. In one embodiment the filter is a cylindrical filter dimensioned to a standard. In another embodiment the mask is pneumatically sealable around the face or head of the user to prevent contaminants form entering the mask.
[0019] The inventions is also directed to a kit comprising the protective mask interface device.
[0020] As used herein the term fluid or fluidic communication and similar terms refer to a pneumatically efficient communication to prevent substantial loss of airflow continuity and where air pressure is concerned to prevent a substantial loss of air pressure. What may be substantial in one type of application may not be in another. The term fluid communication is used distinctly from a sealed communication that is required to prevent noxious elements from entering the mask. The rolled sleeve of resilient material may be adapted for both fluid and sealed types of types communication, though the context in which it is used may not require the latter type of communication. The term respiratory device is used broadly to refer to any device that would be useful for coupling with a mask and mask filter including an additional filter, an air pressure generator, a source of oxygen etc. The air pressure generator may of the type that is manually operable to generate pressure or a source of compressed air. Optionally the protective mask filter interface device of the invention is coupled to an electrically powered air pressure generator. Optionally this device is included in a kit with an expiratory port interface assembly as generally defined herein with optional fluidic connection to a pressure sensor. Optionally, the kit further comprises one more of parts 100 , 300 and 400 ( 400 , if the device includes a pressure sensor and the pressure sensor is not in the expiratory port interface assembly) as described hereafter. Optionally, the protective mask interface is fluidically connected to a blower. Optionally this latter device has any one or more of the features of the air pressure generator assembly defined above and hereinafter.
[0021] Optionally, the rollable sleeve of elastic material includes circular lip. Optionally the lip is approximately 0.25 inches in diameter. Optionally the intended lip portion is integrally formed with the sleeve, loosely rolled on itself, at one end, and glued to form the lip diameter. Optionally the sleeve is positionable in relation to the receptacle so as to free the mouth of the receptacle to receive the mask filter. To this end, the receptacle optionally comprises an annular indent portion to seat the sleeve in a rolled position proximal to the mouth of the receptacle. This annular indent serves as one type of means to resist inadvertent unrolling. Such “unroll resistor” may take a variety of forms and the may comprise one or more devices such as fasteners for example a Velcro type fastener. The annular groove may be of smaller diameter than the widest diameter of the receptacle. Optionally the receptacle slopes to a smaller diameter at its mouth in order to enable the cuff to be rolled quickly over the first portion of the mask filter so that it is quickly held in place while it is fully unrolled. Another form of unroll resistor may be an annular bead of wider diameter than the point of attachment of the sleeve so as to provide a cuff retaining hump.
[0022] A variety of different sleeve materials of a circumferentially stretchable and optionally noxious resistant nature are well known to those skilled in the art. For example a suitable material is a neoprene covered latex material. This material may be cotton-flocked. This material may have a thickness of approximately 30 mils and may be sized to stretch circumferentially to a diameter 10-25% (optionally between 10 and 15%) greater than its resting diameter in order to form a tight fit over the mask filter. The lip may be formed to have a smaller diameter than the rest of the sleeve (for example 5% smaller). Optionally the length of the sleeve is such that the sleeve, when fully unrolled, positions the lip within a smaller diameter, for example in an indent or optionally behind the mask filter, for example, in the space between the cartridge and the mask.
[0023] In another aspect, the invention is directed to mask interface device for a protective mask of the type having a mask filter and a mask expiratory port, the mask filter having an inspiratory air inlet, the mask expiratory port having an expiratory port valve of the type that is normally closed and openable upon expiration, wherein the expiratory port valve is openable at an expiratory port valve pressure, the device comprising:
[0024] an air pressure generator assembly mountable to the mask in fluid communication with the inspiratory inlet of the mask filter, the air pressure generator assembly including an air pressure generator that is controllable to generate pressurized air at a selected mask air pressure;
[0025] an expiratory port interface assembly comprising at least one opening for venting expired gas to atmosphere and a one-way valve that is positioned to control the flow of expired gas out through the at least one opening, wherein the one-way valve is openable at least one selected valve pressure in response to the flow of expired gas out of the mask expiratory port valve, and wherein the at least one selected valve pressure is preferably greater than the expiratory port valve pressure;
[0026] a pressure measurement device;
[0027] a controller connected to the pressure measurement device to receive pressure measurement device output and operatively connected to the air pressure generator to regulate the air pressure generated by the air pressure generator to achieve the selected mask air pressure in response to output of the pressure measurement device wherein the selected mask air pressure matches a selected valve pressure;
[0028] and wherein the expiratory port interface assembly is mountable to the mask to create a chamber at least partially defined by the said mask expiratory port valve and the one-way valve and wherein said chamber is fluidly connected with the pressure measurement device. The term “matches” means that the selected pressure generated by the air pressure generator equals or is greater than the selected opening pressure of the one-way valve. It is to be understood that the mask interface device is adapted to create a biased unidirectional air into the mask and then out the mask expiratory port valve and through the one-way valve to atmosphere. Optionally, the mask pressure is set to a value that is only slightly greater that the opening pressure of the one way valve so as to maintain flow which maintains the mask expiratory valve sufficiently open to equilibrate the pressure between the mask and chamber or closed volume but otherwise not greater so as to preserve battery power. This flow is generated by the air pressure generator at a target mask pressure that is required for the type of ventilatory support required by the user of the mask and is concomitantly set to maintain the expiratory port valve open almost continuously (except upon sudden inspiration) so that pressure sensor substantially measures the pressure in the mask. Accordingly, the term “closed volume” means a space downstream of the expiratory port valve in fluid communication with the pressure sensor which preferably has a pressure virtually always substantially equilibrated with that of the mask. To accomplish this end this chamber does not need to be sealed and some air escape, for example, through an unsealed one-way valve, serves to maintain a biased airflow that keeps the expiratory port assembly free of contaminants.
[0029] As described above, the expiratory port assembly valve is preferably set at or adjustable to a pressure value that provides positive end expiratory pressure (PEEP). Optionally, the expiratory assembly valve sees atmospheric pressure and provides the selected PEEP value at different atmospheric pressures. Optionally, the selected PEEP value is approximately 10 cm H 2 O. Optionally, the expiratory port interface assembly includes a locking mechanism for securing it to the mask expiratory port. Optionally, the locking mechanism is of a type that is engaged after the expiratory port interface assembly is finally positioned on the mask expiratory port. Optionally, the locking mechanism comprises a slidable ring that slidably engages a sleeve shaped clamp (mounted over the mask expiratory port) by way of cam action.
[0030] According to one aspect of the invention, the air pressure generator creates a biased airflow within the expiratory port assembly such that the expiratory port valve (which may be of the type that normally requires minimal pressure to open) is now “normally” continuously biased into an open position (normally in this case meaning except upon occasional sudden deep inspiration, which only for a short duration desirably closes the mask expiratory port valve to prevent contamination of the interior of the mask) and therefore the pressure sensor is normally measuring the pressure in the mask. Normally, the biased airflow prevents the interior of the mask from contamination. Optionally, the PEEP valve is not sealed and constantly leaks air to enhance the biased airflow.
[0031] The mask interface device of the invention may be used to provide a variety of types of respiratory support, for example pressure cycled types of support such as such as CPAP (typical target mask pressure range: 0-15 cm H 2 O, typical PEEP setting range: 2.5 to 12.5 cm H 2 O), bi-level CPAP (BiPAP), controlled ventilation and assist control ventilation (typical target mask pressure range: on inspiration 0-40 cm H 2 O, on expiration: 0-15 cm H 2 O, typical PEEP inspiratory setting range: 10 to 40 cm H 2 O, typical PEEP expiratory setting range: 0 to 15 cm H 2 O), pressure support (typical target mask pressure range: on inspiration 0-40 cm H 2 O, on expiration: 0-15 cm H 2 O, typical PEEP setting range: 5 to 15 cm H 2 O, and proportional pressure support (typical target mask pressure range: on inspiration 0-40 cm H 2 O, on expiration: 0-15 cm H 2 O, typical PEEP setting range: 5 to 20 cm H 2 O) and volume cycled types of support such as controlled ventilation, assist control ventilation and proportional volume ventilation (bellows fill to a volume set mechanically and then empty—typical volume range: 0-1000 cc, typical PEEP setting range: 2.5 to 15 cm H 2 O). For the sake of convenience, the ventilating pressure (irrespective of value) generated in the mask by the pressure generator will be referred to as a “controlled intra-mask pressure”.
[0032] For controlled ventilation, the microprocessor controller may use a closed loop feedback loop to adjust blower speed to change airway flow (or rate of bellows movement) at a prescribed rate to achieve a target volume in a targeted time period and then may release pressure via PEEP for expiratory time and then repeat the cycle. The microprocessor would provide the required timing and monitor pressure to warn or release pressure if thresholds are exceeded. The motor may of a type capable to deliver 60 LPM at the maximum required peak pressure setting plus accommodate a pressure drop from dirty filter at nominal 12 VDC. An 18 VDC battery provides room for overdriving on a nominal 16-18 VDC to ramp up speeds quickly. Similar in most respects, but by way of contrast, for assist control ventilation inhalation is timed to match patient respiratory rate unless it falls below a preset minimum rate. In the case of proportional volume ventilation, a respiratory effort sensor may be used to determine what pressure to use.
[0033] Depending on the type of support provided, other types of sensors and measurement devices may be useful, for example, those that measure for in-flow and out-flow, airway pressure, airflow, time and respiratory effort such as diaphragm EMG and phrenic nerve discharge.
[0034] Depending on the type of support provided, other type of expiratory port interface assembly valves may be preferred. For example, for BiPAP a preferred valve would be a mechanical pressure relief valve with precalibrated settings adjusted between 2 levels by a motor or other actuator.
[0035] Medical indications for ventilatory support are well known to those medically skilled in the various military, industrial, firefighting, aviation and oil and other mining arts. In military settings typical indications for ventilatory support include cardiovascular diseases such as pulmonary edema, lung disease such as trauma, bleeding, edema, infection, embolization, aspiration of water or other substances, inhalation injury from toxic gases or heat, and assistance in the case of paralysis, loss of chest wall compliance or increased airway or mask resistance.
[0036] According to another aspect, the invention is directed to a method of providing non-invasive positive pressure ventilation in junction with a protective mask of the type having a mask filter and a mask expiratory port, the mask expiratory port having an expiratory port valve of the type that is normally closed and openable upon expiration, the mask filter having an inspiratory air inlet, the method comprising: (a) mounting an air pressure generator (component 1 ) onto the mask in fluid communication with the inspiratory air inlet of the mask filter and b) mounting an expiratory port interface assembly on to the mask expiratory port, the mask expiratory port interface assembly (component 2 ) comprising at least one open end for venting expired gas to atmosphere and a one-way valve that is positioned to control the flow of expired gas out through the at least one opening, and wherein the one-way valve is set to an opening pressure that provides positive end expiratory pressure or PEEP.
[0037] The air pressure generator and expiratory port interface assembly are mounted synchronously or in sequence. In the latter case, the invention is also directed to performing the last in a series of cooperative sequential steps as described hereafter performed by a single or different entities. Optionally, one of the components may be pre-mounted in the course of manufacture or preparation of the device. Optionally, a subject using wearing the mask mounts both components, optionally when wearing the protective mask. Optionally, the air pressure generator is mounted first and turned on before the expiratory port assembly is mounted. Optionally, the mask is in fluid communication with an air-pressure measuring device. Optionally, the air pressure generator is in fluid communication with a controller that controls the pressure generated by the air-pressure generating device in response to the measurements of the air pressure measuring device. Optionally, the method further comprises a step of measuring air pressure in the mask. Optionally, the method further comprises the step of controlling the air pressure generated by the air-pressure generating device in response to measurements obtained by the air-pressure measuring device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1 is a perspective view of a mask interface device of the invention showing the positioning of the mask interface device relative to mask when the user wearing the mask wishes to retrofit the device onto the mask.
[0039] FIG. 2 is a sectional view of the mask interface assembly.
[0040] FIG. 3 shows a mask interface device of the invention retrofitted on to the mask.
[0041] FIG. 4 is an exploded view of the mask interface assembly.
[0042] FIG. 5 is another exploded view of the mask interface device assembly showing a different perspective.
[0043] FIG. 6 shows a partial sectional view of the mask interface device showing the airflow path through the device.
[0044] FIG. 7 is a cross-sectional view of the expiratory port interface assembly.
[0045] FIG. 8 is an exploded view of the expiratory port interface assembly.
[0046] FIG. 9 is an exploded view of the expiratory port interface assembly in section.
[0047] FIGS. 10 a and 10 b show unlocked and locked perspectives of mask expiratory port interface assembly in relation to the mask.
[0048] FIG. 11 is a sectional view of another embodiment of the mask interface device.
DETAILED DESCRIPTION OF THE INVENTION
[0049] As generally shown in FIG. 1 , according to one embodiment of the invention, the mask interface device of the invention may optionally include a mask filter interface assembly 100 and an expiratory port interface assembly 200 which are adapted to fit on to a mask filter 1 and a mask expiratory port 2 , respectively. Optionally, the mask filter is of a generally cylindrical shape. Optionally the mask filter is in cartridge form. The term “mask” is used broadly to include a pneumatically isolated (air-pressure retaining) face or head portion of any protective garment or hood that has a cylindrical mask filter. Optionally, the mask may be of the protective type that is pneumatically sealed for preventing inflow of noxious elements. For military applications, the mask is optionally a M40 gas mask outfitted with the NATO C2 cartridge (thread NATO/EN 148-1, 40 mm). Other masks and cartridges are well known to those skilled in the various military, industrial, firefighting, aviation, mining and medical arts (e.g. see http://www.approvedgasmasks.com/). A typical mask 26 to which various embodiments of the invention may be adapted may have left and/or right inspiratory ports 3 to which a mask filter cartridge 1 can be attached. The cartridge 1 is typically mounted by screwing a threaded portion of the cartridge (seen in FIG. 2 ) into the corresponding threaded portions of the ports 3 (not shown). The mask also typically includes transparent lens elements 7 and a voice communication port 5 and straps 6 which sealably affix the mask to the user's face.
[0050] As shown in FIGS. 1 and 2 , the mask interface device of the invention includes a mask filter interface assembly 100 that includes an air pressure generating device. Optionally the air pressure generating device requires electrical power to run, for example according to one embodiment of the invention, a motor driven blower 180 . The air pressure generator may be powered via a battery pack 1001 associated with an electrical cable 300 . Other types of air pressure generators include pumps and sources of compressed air. According to one embodiment of the invention, as shown in the drawings described hereafter, the air pressure generator is a radial blower (for example model U51DX-012KK5 made by Micronel AG which operates at 12 VDC) and the battery pack 1001 that generates sufficient power to power the blower for the application of interest. The battery pack 1001 may be selected to provide excess power, for example, 18 VDC, to power the blower. The blower motor speed may be controlled with pulse width modulated signals and pressure sensor output may be used for closed-loop feedback to maintain a desired output pressure. Pressure settings for continuous positive airway pressure optionally range from 1 to 15 cm H 2 O. For example, a target mask pressure setting of 10 cm H 2 O with PEEP set at 10 cm H 2 O may be preferred for some applications. The blower is preferably able to run continuously at required peak pressure settings as well as accommodate pressure drops from a dirty filter, at nominal 12 VDC. With extra battery power there is room for overdriving on a nominal 16-18 VDC rail to ramp up speeds quickly. The motor may be ramped up to full speed when a pressure drop of any magnitude is ascertained, in order maintain a continuous pressure level in the mask and biased airflow through the mask expiratory port valve 111 .
[0051] The expiratory port interface optionally includes elements of assembly 200 . According to one embodiment of the invention, the expiratory port interface is in fluid communication with a respiratory treatment parameter measuring device, for example a pressure sensor. Suitable pressure sensors include those that measure pressures in the 0-40 cm H 2 O range and are well known to those skilled in the art.
[0052] Optionally the pressure sensor may be used to control the pressure generated by the air pressure generator using a feedback control mechanism. Optionally, the pressure sensor 2001 (seen in FIG. 4 ) is located in proximity to a control board 130 which supports a controller (not shown) that receives output from the pressure sensor 2001 and uses this output to control the pressure applied by the air pressure generator to control the intra-mask air pressure. Optionally, the expiratory port interface assembly includes an air sampling port 18 shown in FIGS. 6 and 7 to sense pressure within the expiratory port interface assembly. The sampling port 18 is optionally in fluid communication via conduit 400 with the pressure sensor, which may be optionally located in the housing of the mask filter interface assembly 100 . When the expiratory port interface assembly 200 is secured to the mask expiratory port 3 expired air vents to atmosphere via apertures 44 .
[0053] As shown in FIGS. 2 , 3 , 4 , 5 and 6 the air pressure generator assembly is fitted with a cuff 14 , which includes a sleeve portion 16 rolled around a circular lip portion 20 best shown in FIGS. 2 and 4 . When the sleeve portion is snugly rolled around the lip the sleeve may be easily unrolled over the mask filter cartridge.
[0054] As shown more particularly in FIG. 2 , according to one embodiment of the invention, the mask filter interface assembly 100 may optionally be adapted to receive or house an air pressure generator in the form of a blower 180 . The mask filter interface assembly 100 may comprise two primary housing elements 102 and 104 . Housing element 102 is the mask filter interface portion of the housing and housing element 104 interfaces with the blower 180 . Housing element 102 comprises a receptacle portion 108 for sliding over a mask filter cartridge.
[0055] As seen in FIG. 4 , 5 , and in some respects 6 , a u-shaped slot defines air channel portion 112 of the housing 102 and aligns with the air inlet aperture 4 on the mask filter cartridge 1 (see also FIG. 4 ). Referring also to FIG. 4 , housing element 102 also comprises an annular indent portion 116 (best seen in FIGS. 2 and 4 ), which optionally extends entirely around the receptacle portion 108 of the housing 102 , in proximity to the mouth of the receptacle 109 and which optionally serves as both a seat for the cuff 14 and a point of attachment of the free end of the sleeve 105 (for example using a suitable adhesive) opposite the other free end defined by the lip portion 20 . Receptacle portion 108 optionally also includes a ramp portion 110 which is of intermediate diameter relative the mask cartridge diameter and the largest diameter of the annular indent portion 116 of the receptacle 108 . This ramp portion facilitates rolling the cuff 14 down onto the smaller diameter mask filter cartridge 1 . Thus, when a subject wearing the mask positions the mask interface assembly onto the cartridge an initial gripping force is applied to the cartridge to quickly secure its positioning pending complete unrolling of the cuff. As described above, cuff 14 comprises a sleeve portion 16 (best shown in FIG. 3 ) and a circular lip portion 20 , which provides a suitably shaped surface onto which the cuff sleeve 16 may be rolled and unrolled. Housing element 102 further comprises an air inlet portion 119 , which is in operative alignment with the air inlet port 150 of the blower 180 . The air inlet portion of housing element 119 comprises slot-like apertures 126 which may be integrally formed with this portion of the housing. Filter 140 , bolster 142 , and spacing ring 144 are generally seated within the cone shaped portion 119 of housing element 102 , bolster 142 having a rigid mesh-like constitution serving to support the filter 140 .
[0056] As shown in FIGS. 2 , 4 and 5 housing element 104 comprises an inclined ramp portion 146 , which deflects air emerging from the outlet port 182 of the blower so that it deflected through slot 112 and into intake port 4 of the mask filter cartridge 1 .
[0057] As shown in FIGS. 4 and 5 , housing element 102 includes a plurality of smaller ports 118 , 120 , 122 and 124 , respectively. Circular port 118 receives the air-pressure sampling conduit 400 shown in FIGS. 1 and 3 while circular port 120 receives electrical cable 300 . The conduit 400 and cable 300 both interface with controller elements in the control board 130 . Conduit 400 slides over an air conduit interface port 2001 a of a pressure-sensing device 2001 on the control board 130 . Triangular reference port 124 is an atmospheric pressure reference port. A conduit (not shown) leads from cylindrical interior portion of this port to a pressure measurement device on the control board 130 . By measuring atmospheric pressure and pressure in the mask the controller is able to adjust the speed of the blower motor to maintain a constant or varying desired pressure above atmospheric pressure (as the downstream side of the one way valve in the expiratory port interface assembly sees atmospheric pressure via apertures 44 ). Triangular port 122 is a vent port for the space containing the control board. This enables pressure to be equalized within this space and atmosphere. Filter elements 117 recessed within ports 122 and 124 prevent the entry debris via these ports. Fastener receptacles 130 a and support element 130 b support the control board 130 in spaced relation to the back-plate 108 a of receptacle 108 . Apertures 130 c (for receiving fasteners—not shown) the control board 130 interface align with receptacles 130 a.
[0058] The expiratory port interface assembly is described in detail in FIGS. 6 , 7 , 8 , 9 , 10 a and 10 b.
[0059] By way of overview, as shown in cross-section in FIGS. 7 and 9 , components of the expiratory port interface assembly include toothed gripping element 16 , gasket 30 and valve seat element 28 , which directly interface with mask expiratory port 2 (shown in FIG. 7 with dotted lines to illustrate the interface).
[0060] By way of overview with initial reference to FIG. 6 , and then FIGS. 7 , 8 , 9 , 10 a and 10 b using a one way airflow path from blower air intake port 150 →through blower outlet port 182 →in filter inlet port 4 →out mask expiratory port valve flap 111 (not seen)→out expiratory port interface assembly valve flap 144 →out expiratory port interface apertures 44 - - - to provide a directional frame of reference for airflow, valve seat element 28 defines a L-shaped annular seat 993 for gasket 30 on its upstream side and an annular valve seat 998 for compression spring 888 mounted valve flap 144 on its downstream side. Valve flap 114 is exposed to atmospheric pressure via apertures 44 on its downstream side.
[0061] More generally, one way expiratory port interface assembly valve (shown as comprising spring elements 888 , valve seat 998 and valve flap 144 ) may be a mushroom valve, a spring actuated valve, a fixed orifice or a leak voltage controlled variable orifice valve. Silicone valves made by liquid injection molding and sold under the trademarks SureFlo and MediFlo are optional alternatives (http://www.Imselastovalves.com/mediflosureflo%20design.htm).
[0062] By way of overview, as best shown in FIGS. 7 and 9 , when the expiratory port interface assembly 200 is secured onto mask expiratory port 2 , the inner walls 2 b of mask expiratory port 2 , the inner walls 28 a of valve seat element 28 , the downstream side of mask expiratory port flap 111 and the upstream side of valve flap 144 define, in effect, a closed volume or chamber which is in direct fluid communication with air pressure sampling port 18 . The term “closed volume” as used herein refers to a chamber defined in part by an one-way upstream valve (in one embodiment the mask expiratory port valve) that normally seals upon inspiration and a one-way downstream valve (expiratory port interface assembly valve) that is openable in response to at least one set pressure and wherein both valves are biased into a closed position pending creation of a biased airflow (by turning on the blower 180 —optionally, after the mask interface assembly is secured and before the expiratory port interface assembly is secured) to establish fluidic continuity between the mask and the otherwise normally closed volume.
[0063] As described above, according to one aspect, the invention is directed to a mask interface device which is adapted to provide positive pressure ventilatory assistance with feedback loop pressure control that can be rapidly deployed by an individual in a contaminated environment without removing the mask or compromising its protective structural integrity. Optionally, by creating the chamber as aforesaid which (absent airflow) is biased to be a closed volume and despite the imposed positioning of the air pressure sampling port downstream of the of mask expiratory port flap 111 (so as not compromise the structural integrity of the mask), pressure can be measured in the mask from within the chamber by using the controller to maintain an airflow that biases the mask expiratory port flap 111 and expiratory port interface flap 114 into an open position. This is optionally accomplished by maintaining the mask pressure at a predetermined level that equals or exceeds the opening pressure of flap 114 . The continuously biased flow of air prevents contaminants from building up in the transiently closed volume and entering the mask via mask expiratory port flap 111 . A suitable biased airflow may be also maintained when closure of the valve flap 114 is unsealed.
[0064] By way of overview, the expiratory port assembly 200 also comprises a locking ring 12 , which cooperates with toothed gripping element 16 and gasket 30 to secure the expiratory interface assembly 200 to the mask expiratory port.
[0065] By way of overview, expiratory port interface assembly 200 also comprises housing element 8 having apertures 44 to vent expired gases to atmosphere, a valve flap 114 upstream thereof and compression springs 888 which maintain the one way valve flap 114 in a closed position unless pressure in the expiratory port interface assembly upstream of the valve exceeds the flap opening pressure (normally when the blower is on due to biased airflow and especially during expiration), as dictated by the springs and atmospheric pressure (seen by the valve flap via apertures 44 ). Housing element 8 also comprises flanges 789 which define circumferential slots to retain the locking ring 12 for sliding movement over the surface of toothed gripping element 16 . Housing element 8 also comprises a port 8 a for receiving the conduit 400 and cylindrically shaped receptacles 114 b for seating the compression springs 888 and pins 114 a . Receptacles 114 c (shown in FIG. 6 ) receive pins 114 a on the downstream side of valve seat element 28 .
[0066] As shown in FIGS. 8 and 9 , locking ring 1 comprises a ring portion 777 (shown as spanning the longitudinal distance “B” in FIG. 9 ) and two longitudinally extended gripping portions 775 (having a ridged surface that allow these portions to be more securely gripped by the thumb and index finger of an operator when used to perform the last (locking) step in securing the expiratory interface assembly 200 to the mask expiratory port 2 —gripping portions 775 are shown as spanning the longitudinal distance “A” in FIG. 9 ). Gripping portions 775 have beveled portions 779 that are retained by a plurality of annular flanges 789 of housing element 8 . Beveled portions 779 slidably ride in a longitudinal direction under flanges 789 .
[0067] As seen in FIGS. 8 , 10 a and 10 b showing the direction in which the expiratory port interface assembly 200 is moved to slidably engage the mask expiratory port 2 , shortened toothless finger-like projections 898 of toothed gripping element 16 define slots 1000 that avoid interference with T-shaped pins 825 (pins that normally support a conventional ‘mask expiratory port cap and drinking port assembly’—not shown) and thereby permit the expiratory port interface assembly 200 to slide fully onto the mask expiratory port 2 . The gasket 30 has corresponding slots 1100 for the same purpose. As best shown in cross-section in FIG. 7 , annular shoulder 990 of valve seat element 28 serves as a contact surface for contacting the most projecting portion of the mask expiratory port 2 to define this fully mounted position which in turn corresponds with the position in which tooth-like projections 770 can be locked behind surface 2 c of the mask expiratory port 2 for securely coupling the expiratory port interface assembly 200 onto the mask expiratory port 2 .
[0068] As best seen in FIG. 7 , cylindrical gasket 30 is pressed into a pneumatically efficient interface with mask expiratory port 2 by finger-like projections of gripping element 16 . These finger-like projections are capable of being compressed against the gasket 30 by sliding locking-ring 12 from the an unlocked position ( FIG. 10 a ) in which the surfaces 12 a and 16 a of the locking ring and finger like projections are not are not engaged to exert a compressing cam action against the finger like projections and a second locked position ( FIG. 10 b ) in which the locking ring is longitudinally displaced towards surfaces 16 c of the finger-like projections, these surfaces on the individual finger-like projections collectively defining an annular (the term annular not necessarily implying continuity) ring-retaining lip 700 of the gripping element 16 that projects radially outwardly to retainingly engage abutment surface 12 c of the locking ring 12 . When the ring is moved from the unlocked position into the locked position beveled cam surfaces 12 b and 16 b of the locking ring and finger-like projections, respectively, slide past one another to exert a radial compressive force against the circumferential exterior face 16 a of the finger-like gripping elements to compress them into closer proximity with one another. This in turn applies corresponding compressive forces respectively against corrugated face 30 a of the gasket 30 and face 2 a of the mask expiratory port 2 . In tandem, the radially inwardly projecting tooth-like portions 770 of the finger-like projections move radially inwardly towards a lesser diameter surface 2 d of the mask expiratory port 2 , so as to lock these tooth-like portions behind the retaining surface 2 c of the mask expiratory port 2 .
[0069] As shown in FIG. 11 , in a more general aspect the mask interface device 2000 of the invention may comprise an interface with any respiratory device, for example, any device through which air travels that is functional in conditioning air inspired by the wearer of the mask, the interface, for example, being in the form of port 2002 having a threaded portion 2003 for receiving a second filter 1 a fitted with a mating threaded portion 1 b . Fluidic communication is established between the filters via port 2010 in the interface device. The threaded portion 2003 of the device and the cuff 14 may be adapted to create a sealed communication between the filters 1 and 1 a to prevent noxious elements from entering into the gas mask. The term “air” is used broadly throughout to refer to a gas of any composition pertinent to respiratory assistance, comfort or medical treatment. | A mask interface device is provided for a protective mask of the type having a mask filter and a mask expiratory port, the mask expiratory port having an expiratory port valve of the type that is normally closed and openable upon expiration, the mask filter having an inspiratory air inlet, the mask interface device comprising: a mask interface assembly mountable to the mask and having a mounting interface for mounting an air pressure generator in fluid communication with the inspiratory inlet of the mask filter; and an expiratory port interface assembly mountable to the mask expiratory port and comprising at least one opening for venting expired gas to atmosphere and a one-way valve that is positioned to control the flow of expired gas out through the at least one opening, and wherein the one-way valve is set to an opening pressure that provides positive end expiratory pressure or PEEP. Optionally, this opening pressure is between 2.5 and 20 cm H2O. Optionally, the mask interface device interface directly with the mask filter. In one embodiment of the invention, this interface does not require the filter to have a mating connection and is therefore is universal for a broad class of filters, for example cylindrical filters that project from the mask. | 50,316 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 13/954,735, filed on Jul. 30, 2013, titled “DEVICES AND METHODS FOR CERVIX MEASUREMENT,” now U.S. Pat. No. 8,870,794, which is a continuation of U.S. patent application Ser. No. 13/747,331, filed on Jan. 22, 2013, titled “DEVICES AND METHODS FOR THE CERVIX MEASUREMENT,” now U.S. Pat. No. 8,517,960, which is a continuation of U.S. patent application Ser. No. 12/944,580, filed on Nov. 11, 2010, titled “DEVICES AND METHODS FOR CERVIX MEASUREMENT,” now U.S. Pat. No. 8,366,640, which claims priority to U.S. Provisional Patent Application No. 61/260,520, filed Nov. 12, 2009, entitled “DEVICES AND METHODS FOR CERVIX MEASUREMENT” and U.S. Provisional Patent Application No. 61/369,523, filed Jul. 30, 2010, titled “DEVICES AND METHODS FOR CERVIX MEASUREMENT.” These applications are herein incorporated by reference in their entirety.
INCORPORATION BY REFERENCE
[0002] All publications and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference.
FIELD
[0003] The present invention relates to medical devices and methods of using such devices. More particularly, the invention relates to instruments and methods to measure the length of the cervix in the fornix vaginae and the dilation of the cervix uteri.
BACKGROUND
[0004] Preterm labor, or labor before 37 weeks gestation, has been reported in approximately 12.8 percent of all births but accounts for more than 85 percent of all perinatal complications and death. Rush et al., BMJ 2:965-8 (1976) and Villar et al., Res. Clin. Forums 16:9-33 (1994), which are both incorporated herein by reference. An inverse relationship between cervical length in the fornix vaginae and the risk of preterm labor has also been observed. Andersen et al., Am. J. Obstet. Gynecol. 163:859 (1990); Jams et al., N. Eng. J. Med. 334:567-72 (1996) and Heath et al., and Ultrasound Obstet. Gynecol. 12:312-7 (1998), which all are incorporated herein by reference. Accordingly, many physicians find it useful to examine the cervix in the fornix vaginae as part of normal prenatal care in order to assess risk of preterm labor.
[0005] It has long been known that the cervix normally undergoes a series of physical and biochemical changes during the course of pregnancy, which enhance the ease and safety of the birthing process for the mother and baby. For example, in the early stages of labor the tissues of the cervical canal soften and become more pliable, the cervix shortens (effaces), and the diameter of the proximal end of the cervical canal begins to increase at the internal os. As labor progresses, growth of the cervical diameter propagates to the distal end of the cervical canal, toward the external os. In the final stages of labor, the external os dilates allowing for the unobstructed passage of the fetus.
[0006] In addition to the physical and biochemical changes associated with normal labor, genetic or environmental factors, such as medical illness or infection, stress, malnutrition, chronic deprivation and certain chemicals or drugs can cause changes in the cervix. For example, it is well known that the in utero exposure of some women to diethylstilbestrol (DES) results in cervical abnormalities and in some cases gross anatomical changes, which leads to an incompetent cervix where the cervix matures, softens and painlessly dilates without apparent uterine contractions. An incompetent cervix can also occur where there is a history of cervical injury, as in a previous traumatic delivery, or as a result of induced abortion if the cervix is forcibly dilated to large diameters. Details of the incompetent cervix are discussed in Sonek, et al., Preterm Birth, Causes, Prevention and Management, Second Edition, McGraw-Hill, Inc., (1993), Chapter 5, which is incorporated by reference herein.
[0007] Cervical incompetence is a well recognized clinical problem. Several investigators have reported evidence of increased internal cervical os diameter as being consistent with cervical incompetence (see Brook et al., J. Obstet. Gynecol. 88:640 (1981); Michaels et al., Am. J. Obstet. Gynecol. 154:537 (1986); Sarti et al., Radiology 130:417 (1979); and Vaalamo et al., Acta Obstet. Gynecol. Scan 62:19 (1983), all of which are incorporated by reference herein). Internal os diameters ranging between 15 mm to 23 mm have been observed in connection with an incompetent cervix. Accordingly, a critical assessment in the diagnosis of an incompetent cervix involves measurement of the internal cervical os diameter.
[0008] There are also devices and methods to measure the diameter of the external cervical os. For example, cervical diameter can be manually estimated by a practitioner's use of his or her digits. Although an individual practitioner can achieve acceptable repeatability using this method, there is a significant variation between practitioners due to the subjective nature of the procedure. To address these concerns, various monitoring and measuring devices and methods have been developed. For example, an instrument for measuring dilation of the cervix uteri is described in U.S. Pat. No. 5,658,295. However, this device is somewhat large, leading to a risk of injury to the fundus of the vagina or cervical os. Additionally, it is not disposable and requires repeated sterilization. Another device for measuring cervical diameter is described, for example, in U.S. Pat. No. 6,039,701. In one version, the device described therein has a loop element which is secured to the cervix. The loop expands or contracts with the cervix and a gauge is coupled to the loop for measuring changes in the loop dimension. Such changes can then be detected by electronic means. Accordingly, this device is rather complex and expensive to manufacture.
[0009] Even if a woman is found to have an apparently normal internal cervical os diameter, there may nonetheless be a risk for preterm labor and delivery. Currently, risk assessment for preterm delivery remains difficult, particularly among women with no history of preterm birth. However, the findings that preterm delivery is more common among women with premature cervical shortening or effacement suggest that a measuring the length of the cervix would be predictive for preterm labor.
[0010] Currently, a physician has at least two options to measure the length of the cervix in the fornix vaginae. One such method involves serial digital examination of the cervix by estimating the length from the external cervical os to the cervical-uterine junction, as palpated through the vaginal fornix. Although this is useful for general qualitative analysis, it does not afford an easy nor accurate measurement of the length of the cervix from the external cervical os to the cervical-uterine junction (also described herein as the length of the cervix extending into the vagina) and, therefore, does not provide an accurate assessment of the risk of preterm labor. Despite the use of gloves, digital vaginal exams always carry with them the risk of transmitting infectious agents, especially to the fetal membranes, the lining and/or muscle of the uterus, or to the fetus itself.
[0011] Another method involves real-time sonographic evaluation of the cervix. This method provides relatively quick and accurate cervical dimensions. However, it requires expensive equipment, highly skilled operators, as well as skill in interpretation of results, which are all subject to human error. Additionally, there is a risk that the probe that must be inserted into the vagina as part of the procedure may cause injury if not inserted with care. Also, due to the expense of the procedure many women, especially those without proper health insurance, cannot afford to have a sonographic test performed.
[0012] It would be beneficial if there were an instrument a practitioner could use to measure the cervix quickly and accurately, and with little material expense. Although there are several instruments available for determining various dimensions of the uterus, there is no suitable instrument for measuring the length of the cervix in the fornix vaginae. For example, U.S. Pat. No. 4,016,867 describes a uterine caliper and depth gauge for taking a variety of uterine measurements, which although useful for fitting an intrauterine contraceptive device, is not capable of measuring the length of the cervix in the fornix vaginae due to interference by the caliper's wings. In fact, similar devices described in U.S. Pat. Nos. 4,224,951; 4,489,732; 4,685,474; and 5,658,295 suffer from similar problems due to their use of expandable wings or divergeable probe tips. These devices are also relatively sophisticated, making them expensive to manufacture and purchase. U.S. Pat. No. 3,630,190 describes a flexible intrauterine probe, which is particularly adapted to measuring the distance between the cervical os and the fundus of the uterus. The stem portion of the device has a plurality of annular ridges spaced apart from each other by a predetermined distance, preferably not more than one-half inch apart. However, this device is not adapted for accurately measuring the length of the cervix in the fornix vaginae because of the lack of an appropriate measuring scale and a stop for automatically recording the measurement.
[0013] There exists a need for a simple and inexpensive device that can be used to determine the length of the cervix in the fornix vaginae and, thus, predict the risk of preterm labor, as well as other conditions. There is also a need for such a device that can measure the dilation of the cervix uteri, to provide an overall assessment of the cervix and to determine the particular stage of labor. Ideally, the device should be adapted for use by a physician or obstetrician or even a trained nurse in the doctor's office or clinic. Preferably, the device should be sterile and disposable. In addition, it is desirable that device be able to lock after a measurement is taken to ensure that the measurement does not change between the time a user takes the measurement and removes the device from the patient to read the measurement. The present invention satisfies these needs and provides related advantages as well.
SUMMARY OF THE DISCLOSURE
[0014] In general, in one aspect, a device for measuring a length of a cervix includes an elongate measurement member, a hollow member, a flange, a handle, and a locking mechanism. The elongate measurement member extends along a longitudinal axis and includes a measurement scale thereon. The hollow member is coaxial with and disposed over the elongate measurement member. The flange is offset from the longitudinal axis and attached to a distal end of the hollow member. The handle is attached to a proximal end of the measurement member. The locking mechanism is configured, when locked, to fix the hollow member relative to the measurement member and, when unlocked to allow the hollow member to slide along the measurement member and rotate about the longitudinal axis so as to place the flange in a desired position without moving the measurement scale.
[0015] This and other embodiments can include one or more of the following features. The proximal end of the hollow member can be slideable into the handle. The flange can have an opening through which the measurement member can advance distally. The flange can have a flat surface perpendicular to the longitudinal axis. The locking mechanism can include a button, the button including a through-hole configured such that the hollow member can slide therethrough and a lock channel configured such that the hollow member cannot slide therethrough. The button can further include at least one lock ramp between the through-hole and the lock channel. The measurement scale can be a millimeter scale. The measurement scale can extend from 0 mm to 50 mm. The hollow member can be transparent. The measurement scale can include an opaque background. The device can further include an indicator line on the hollow member. The indicator line can be a color other than black.
[0016] In general, in one aspect, a method for measuring a length of a cervix includes: holding a handle of a device, the device further including an elongate measurement member having a measurement scale thereon, a hollow member coaxial with and disposed over the elongate measurement member, and a flange attached to a distal end of the hollow member; rotating the hollow member about the elongate measurement member so as to place the flange at a desired orientation without rotating the measurement scale; advancing the device distally within a vagina until the flange contacts a cervix at an external uterine opening; advancing the measurement member distally within the vagina until a distal end of the measurement member contacts a cervical uterine junction at a fornix vaginae; locking the measurement member relative to the hollow member by locking a locking mechanism on the handle; and observing a position of the hollow member with respect to the measurement member to determine a length of the cervix in the fornix vaginae.
[0017] This and other embodiments can include one or more of the following features. Advancing the measurement member distally can include sliding the hollow member into the handle. The flange can be offset from a longitudinal axis of the measurement member. The locking mechanism can include a button having a through-hole and a lock channel, and wherein locking the locking mechanism comprises pushing the button such that the hollow member moves into the lock channel and cannot slide through the through-hole. Observing the position can include observing an indicator line on the hollow member with respect to a measurement scale on the measurement member. The method can further include determining the risk of miscarriage based upon the length of the cervix in the fornix vaginae, wherein the length of the cervix in the fornix vaginae is inversely related to the risk of miscarriage. The method can further include predicting the ease of inducing labor, wherein the length of the cervix in the fornix vaginae is inversely related to the ease of inducing labor. The method can further include determining the risk of preterm labor based upon the length of the cervix in the fornix vaginae, wherein the length of the cervix in the fornix vaginae is inversely related to the risk of preterm labor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The novel features of the invention are set forth with particularity in the claims that follow. A better understanding of the features and advantages of the present invention will be obtained by reference to the following detailed description that sets forth illustrative embodiments, in which the principles of the invention are utilized, and the accompanying drawings of which:
[0019] FIG. 1 a is an illustration of a measuring device, according to one embodiment.
[0020] FIGS. 1 b - 1 e are additional views of the measuring device of FIG. 1 a.
[0021] FIG. 2 a is an illustration of a measuring device, according to one embodiment.
[0022] FIGS. 2 b - 2 e are additional views of the measuring device of FIG. 2 a.
[0023] FIG. 3 a is an illustration of a measuring device, according to one embodiment.
[0024] FIGS. 3 b - 3 d are additional views of the measuring device of FIG. 3 a.
[0025] FIG. 4 a is an illustration of a measuring device, according to one embodiment.
[0026] FIGS. 4 b - 4 g are additional views of the measuring device of FIG. 4 a.
[0027] FIG. 5 a is an illustration of a measuring device, according to one embodiment.
[0028] FIGS. 5 b - 5 d are additional views of the measuring device of FIG. 5 a.
[0029] FIG. 6 a is an illustration of a measuring device, according to one embodiment.
[0030] FIGS. 6 b - 6 f are additional views of the measuring device of FIG. 6 a.
[0031] FIG. 7 a is an illustration of a measuring device, according to one embodiment.
[0032] FIGS. 7 b - 7 h are additional views of the measuring device of FIG. 7 a.
[0033] FIG. 8 is an illustration of a measuring device in use for measuring the vaginal cervix.
DETAILED DESCRIPTION
[0034] The present invention provides various devices and methods for determining dimensions of female reproductive organs. For example, the devices described herein are particularly adapted for determining the length of the cervix in the fornix vaginae, which, as described above, is related to the risk of preterm labor in an individual. The devices can also be suited for determining the dilation of the cervix uteri, for predicting the risk of preterm labor or the particular stage of delivery.
[0035] It is, however, contemplated herein, that the invention is not limited to determining various dimensions of female reproductive organs. For example, the invention can be usable for determining the dimension of any body cavity or passageway where such a device would be insertable, such as a vagina, uterus, mouth, throat, nasal cavity, ear channel, rectum, and also to any cavity created and opened by surgery, for example, during chest, abdominal or brain surgery.
[0036] The devices described herein are also preferably fabricated from relatively inexpensive materials and the measurement is quick to perform. This allows the practitioner to repeat the test over time and therefore to more closely monitor a woman's pregnancy and risk for preterm labor. It is also contemplated that the device can record the various measurements automatically, where the only input required by the practitioner is the proper insertion of the device into the body cavity or passageway. This can be accomplished by the use of a flange to stop progression of the hollow member of the device while still allowing the measurement member to be advanced within the body.
[0037] FIG. 1 a illustrates a measuring device 100 that includes an elongated measurement member 102 and an elongated hollow member 104 . The elongated measurement member 102 is adapted to be inserted into the hollow member 104 , and specifically into a lumen of the hollow member. Handle 106 can be positioned on a proximal portion of the measuring device, as shown in FIG. 1 a . In one embodiment, the handle is molded from the same material as the measurement member 102 . In other embodiments, the handle can be a rubber or foam component that is fitted on to and over the proximal end of the measuring device.
[0038] A measurement scale 108 can be disposed along a portion of the measurement member 102 . The measurement scale 108 can include any number of a series of visual markings on the measurement member 102 which relate a measurement or distance. In a particularly preferred embodiment, the measurement scale 108 includes a plurality of millimeter (mm) incremental markings and a plurality of centimeter (cm) incremental markings.
[0039] As shown in FIG. 1 a , the measurement scale 108 can be color-coded to indicate the relative risks of preterm delivery for a cervix length falling within each respective colored region. For example, in one embodiment, a first zone 132 can include the incremental markings less than 2 cm and can be coded in a first color, such as red, a second zone 134 can include the incremental markings from 2 to 3 cm and can be coded in a second color, such as yellow, and the third zone 134 can include the incremental markings from 3 to 5 cm and can be coded in a third color, such as green. In FIG. 1 a , the measurement scale is color-coded into three regions that each visually represents the relative risks of preterm delivery for a cervix length falling within the respective region. For instance, the first zone 132 indicates a shorter cervix, and therefore a higher risk of preterm delivery, than the second zone 134 , which indicates a cervix length that reflects a higher risk of preterm delivery than the green zone 136 .
[0040] A flange 110 that is shaped for non-abrasive contact with tissue can be disposed on a distal portion of measuring device 100 . The flange can be preferably flat and spherically or conically shaped. Alternatively, however, the flange may be any other non-abrasive shape to reduce irritation and scraping of the cervical canal, fundus of the vagina or perforation of the fundus of the uterus. The main body of the flange is also preferably offset from the longitudinal axis of the measuring device 100 . Additionally, the flange can include an opening 112 through, which measurement member 102 may be advanced distally after the flange contacts a bodily surface. Preferably, the flange is secured to the distal end of the hollow member 104 using a suitable attachment means, such as, e.g., an adhesive. Alternatively, the flange may be formed as an integral component of the hollow member 104 .
[0041] FIGS. 1 b - 1 d illustrate the operation of the measuring device 100 as it is used to measure the length of a cervix. When the distal end of the measurement member 102 is flush with the flange, as shown in FIG. 1 b , the device is in a starting configuration. The device 100 can be advanced into the vagina until the flange 110 is placed into contact with the end of the cervix at the external uterine opening. At this point, further forward progress of the hollow member 104 within the cervical canal or further within the body is prevented as a result of the contact between flange 110 and the end of the cervix at the external uterine opening. Since flange 110 is preferably offset from the longitudinal axis of measuring device 100 , in one embodiment the flange is placed both in contact with the end of the cervix and also covering the external uterine opening. As a result, the device can oriented so that measurement member 102 is still able to be progressed within the fornix, rather than being advanced through the uterus, since the body of flange 106 is, with this method, covering the external uterine opening.
[0042] Subsequently, as shown in FIGS. 1 c - 1 d , a distal portion of measurement member 102 can continue to be advanced through opening 112 of flange 110 until the distal end contacts a wall of the body, such as, e.g., the anterior fornix. When the distal end of the measurement member is advanced beyond the flange the device is in a measuring configuration. FIG. 1 c shows a side view of the measurement member in the measuring configuration, and FIG. 1 d shows a top down view of the device in the measuring configuration. It can be seen in FIG. 1 d , for example, that the measurement member has been advanced 4 cm beyond the flange. The length of the cervix can then be measured by observing the position of the proximal end of the hollow member 104 along the measurement scale 108 of the measurement member 102 . In another embodiment, a method of measurement comprises advancing the distal end of the measurement member 102 to the wall of the body, such as the anterior fornix, and then advancing the hollow member 104 so that the flange 110 is placed into contact with the end of the cervix at the external uterine opening.
[0043] Referring now to FIG. 1 e , a locking mechanism 114 can be located on the measuring device 100 that allows a user to secure the measurement member 102 within the hollow member 104 after the measurement of a body part, such as, e.g., the length of the cervix. In FIG. 1 e , the locking mechanism 114 includes button 116 , cantilever arm 118 , detents 120 , and opening 122 . When the locking mechanism is in the locked configuration, as shown in FIG. 1 e , the cantilever arm 118 engages detents 120 on the inside of hollow member 104 . The cantilever arm can be integral to the measurement member 102 , for example. To allow sliding of the measurement member within the hollow member, button 116 can be pressed inwards towards opening 122 , causing cantilever arm 118 to disengage detents 120 and allow sliding.
[0044] For example, to take a measurement of a body part, a user can insert the measuring device 100 into the patient. The user can then press the button 116 inwards to disengage the cantilever arm and allow the measurement member to slide within the hollow member. After the measurement of a body part is taken with the device, the user can release the button, causing the cantilever arm to engage the detents and lock the position of the measurement member 102 within the hollow member 104 . This allows the user to remove the device from the patient to read the measurement scale while ensuring that movement of the measurement member 102 proximally or distally within the hollow member 104 is prevented.
[0045] During a measurement procedure, a user can hold handle 106 with the dominant hand like a dart, and can hold the barrel of the hollow member 104 with the non-dominant hand. The user can activate button 116 with the dominant hand to temporarily unlock the measuring device, allowing the hollow member to slide with respect to the measurement member.
[0046] Referring now to FIG. 2 a , another embodiment of a measuring device 200 is shown. Measuring device 200 includes many of the features of measuring device 100 , described above and illustrated in FIGS. 1 a - 1 e . For example, measuring device 200 includes an elongated measurement member 202 slidably disposed within an elongated hollow member 204 . Handle 206 can be positioned on a proximal portion of the measuring device, and measurement scale 208 , such as a color-coded measurement scale, can be disposed on the measurement member 202 . The measuring device can further include a flange 210 on a distal portion of the device, and an opening 212 that allows the measurement member 202 to extend distally beyond the hollow member 204 .
[0047] As described above, the device 200 can have a starting configuration, as shown in FIG. 2 b , and a measuring configuration, as shown in FIG. 2 c . The measuring device 200 can further include a locking mechanism 214 . The locking mechanism allows a user to lock the measurement member 202 within the hollow member 204 , to prevent movement of the measurement member with respect to the hollow member after a measurement is taken. In the embodiment shown in FIGS. 2 a - 2 e, the locking mechanism 214 is disposed on the hollow member 204 .
[0048] Referring now to FIG. 2 d , which is a side view of the locking mechanism 214 , and FIG. 2 e , which is a cross sectional view of the locking mechanism 214 , the locking mechanism can further include pads or buttons 216 , tabs 218 , and detents 220 . The buttons 216 and tabs 218 can be integral to the hollow member 204 , and the detents 220 can be integral to the measurement member 202 , for example. In the embodiment shown in FIGS. 2 d - 2 e, the locking mechanism includes two buttons 216 . However, in other embodiments, the locking mechanism can include only a single button, or alternatively, can include more than two buttons.
[0049] When the locking mechanism 214 is in a locked configuration, as shown in FIG. 2 d , the tabs engage detents 220 , preventing any movement of the measurement member with respect to the hollow member 204 . However, when the buttons 216 are depressed inwards by a user, as shown in FIG. 2 e , the tabs 218 can be squeezed outwards, as indicated by arrows 224 , causing them to disengage from detents 220 . This allows a measurement to be taken by sliding the measurement member 202 within the hollow member 204 .
[0050] To take a measurement of a body part, a user can insert the measuring device 200 into the patient. The user can then press the button or buttons 216 inwards to cause the tabs 218 to squeeze outwards disengaging detents 220 , thereby allowing the measurement member to slide within the hollow member. After the measurement of a body part is taken with the device, the user can release the buttons, causing the tabs to engage the detents and lock the position of the measurement member 202 within the hollow member 204 . This allows the user to remove the device from the patient to read the measurement scale while ensuring that movement of the measurement member 202 proximally or distally within the hollow member 204 is prevented.
[0051] During a measurement procedure, a user can hold handle 206 with the dominant hand like a dart, and can hold the barrel of the hollow member 204 with the non-dominant hand. The user can activate button 216 with the non-dominant hand to temporarily unlock the measuring device, allowing the hollow member to slide with respect to the measurement member.
[0052] Referring now to FIG. 3 a , yet another embodiment of a measuring device 300 is shown. Measuring device 300 includes many of the features of measuring device 100 , described above and illustrated in FIGS. 1 a - 1 e . For example, measuring device 300 includes an elongated measurement member 302 slidably disposed within an elongated hollow member 304 . Handle 306 can be positioned on a proximal portion of the measuring device, and measurement scale 308 , such as a color-coded measurement scale, can be disposed on the measurement member 302 . The measuring device can further include a flange 310 on a distal portion of the device, and an opening 312 that allows the measurement member 302 to extend distally beyond the hollow member 304 .
[0053] As described above, the device 300 can have a starting configuration, as shown in FIG. 3 b , and a measuring configuration, as shown in FIG. 3 c . In addition, a locking mechanism 314 can be located on the measuring device 300 that allows a user to secure the measurement member 302 within the hollow member 304 after the measurement of a body part, such as, e.g., the length of the cervix.
[0054] In FIG. 3 d , the locking mechanism 314 includes button 316 , cantilever arm 318 , and detents 320 . When the locking mechanism is in the locked configuration, as shown in FIG. 3 d , the cantilever arm 318 engages detents 320 on the outside of measurement member 302 . The cantilever arm can be integral to the hollow member 304 , for example. To allow sliding of the measurement member within the hollow member, button 316 can be pressed inwards, causing cantilever arm 318 to disengage detents 320 and allow sliding.
[0055] For example, to take a measurement of a body part, a user can insert the measuring device 300 into the patient. The user can then press the button 316 inwards to disengage the cantilever arm and allow the measurement member to slide within the hollow member. After the measurement of a body part is taken with the device, the user can release the button, causing the cantilever arm to engage the detents and lock the position of the measurement member 302 within the hollow member 304 . This allows the user to remove the device from the patient to read the measurement scale while ensuring that movement of the measurement member 302 proximally or distally within the hollow member 304 is prevented.
[0056] During a measurement procedure, a user can hold handle 306 with the dominant hand like a dart, and can hold the barrel of the hollow member 304 with the non-dominant hand. The user can activate button 316 with the non-dominant hand to temporarily unlock the measuring device, allowing the hollow member to slide with respect to the measurement member.
[0057] Referring now to FIG. 4 a , another embodiment of a measuring device 400 is shown. Measuring device 400 includes many of the features of measuring device 100 , described above and illustrated in FIGS. 1 a - 1 e . For example, measuring device 400 includes an elongated measurement member 402 slidably disposed within an elongated hollow member 404 . Handle 406 can be positioned on a proximal portion of the measuring device, and measurement scale 408 , such as a color-coded measurement scale, can be disposed on the measurement member 402 . The measuring device can further include a flange 410 on a distal portion of the device, and an opening 412 that allows the measurement member 402 to extend distally beyond the hollow member 404 .
[0058] As described above, the device 400 can have a starting configuration, as shown in FIG. 4 b , and a measuring configuration, as shown in FIG. 4 c . In contrast to the embodiments described above, the hollow member 404 of the measuring device 400 in FIGS. 4 a - 4 e slides into the handle 406 when a measurement is taken. The measurement member 402 remains fixed in position with respect to the handle, which allows the measurement member to extend distally beyond the flange 410 during measurements.
[0059] The measuring device 400 can further include a locking mechanism 414 . The locking mechanism allows a user to lock the hollow member 404 within the handle 406 , to prevent movement of the hollow member with respect to the measurement member after a measurement is taken. In the embodiment shown in FIGS. 4 a - 4 e, the locking mechanism 414 can comprise a button 416 with a through-hole (not shown). In FIG. 4 d , the device is shown in an unlocked configuration, in which the through-hole is aligned with the hollow member 404 to allow the hollow member to travel therethrough. When the device is in a locked configuration, as shown in FIG. 4 e , the through-hole pushes against the hollow member, preventing movement of the hollow member with respect to the measurement member.
[0060] FIG. 4 f shows a cross-sectional view of locking mechanism 414 , button 416 , and hollow member 404 . The button geometry is designed to operate smoothly with a low actuation force to engage the locking mechanism. The open channel 418 of the button allows the hollow member 404 to slide freely into the handle when a measurement is being taken. When the button is depressed, the lock ramps 420 are forced to slide over the hollow member 404 , which provides tactile and audible feedback that the device is in the locked position. The design of the lock ramps, including height and ramp angle affects the effort levels required to activate the button. The width of the lock channel 422 is designed to be narrower than the overall outside diameter of the hollow member 404 , so that the interference between the two surfaces provides a retention force to maintain the measurement while the device is removed from the patient. In some embodiments, the locking mechanism does not include the lock ramps 420 . In other embodiments, the lock channel 422 can be tapered to provide a frictional, locking fit for hollow member 404 when button 416 is depressed, as shown in FIG. 4 g.
[0061] For example, to take a measurement of a body part, a user can insert the measuring device 400 in an unlocked configuration (e.g., where the through-hole is aligned to allowed movement of the hollow member) into the patient. After the measurement of a body part is taken with the device, the user can press the button 416 , causing the through-hole to press against the hollow member to prevent movement of the hollow member. This allows the user to remove the device from the patient to read the measurement scale while ensuring that movement of the measurement member 402 proximally or distally within the hollow member 404 is prevented.
[0062] During a measurement procedure, a user can hold handle 406 with the dominant hand like a dart, and can hold the barrel of the hollow member 104 with the non-dominant hand. After taking a measurement, the user can activate button 416 with the dominant hand to lock the measuring device, preventing the hollow member from sliding with respect to the measurement member.
[0063] Referring now to FIG. 5 a , another embodiment of a measuring device 500 is shown. Measuring device 500 includes many of the features of measuring device 100 , described above and illustrated in FIGS. 1 a - 1 e . For example, measuring device 500 includes an elongated measurement member 502 slidably disposed within an elongated hollow member 504 . Syringe-style handle 506 can be positioned on a proximal portion of the measuring device, and measurement scale 508 , such as a color-coded measurement scale, can be disposed on the measurement member 502 . The measuring device can further include a flange 510 on a distal portion of the device, and an opening 512 that allows the measurement member 502 to extend distally beyond the hollow member 504 .
[0064] As described above, the device 500 can have a starting configuration, as shown in FIG. 5 b , and a measuring configuration, as shown in FIG. 5 c . Similar to the embodiment of measuring device 400 described above and illustrated in FIGS. 4 a - 4 e, the hollow member 504 of the measuring device 500 in FIGS. 5 a - 5 d slides into the handle 506 when a measurement is taken. The measurement member 502 remains fixed in position with respect to the handle, which allows the measurement member to extend distally beyond the flange 510 during measurements.
[0065] The measuring device 500 can further include a locking mechanism 514 . The locking mechanism allows a user to lock the hollow member 504 within the handle 506 , to prevent movement of the hollow member with respect to the measurement member after a measurement is taken. In the embodiment shown in FIG. 5 d , the locking mechanism 514 can comprise a button 516 with a through-hole (not shown). Similar to the embodiments described above in FIGS. 4 a - 4 e , the device can have an unlocked configuration, in which the through-hole is aligned with the hollow member 504 to allow the hollow member to travel therethrough. The device can also have a locked configuration, in which the through-hole pushes against the hollow member thereby preventing movement of the hollow member with respect to the measurement member.
[0066] To take a measurement of a body part, a user can insert the measuring device 500 in an unlocked configuration (e.g., where the through-hole is aligned to allowed movement of the hollow member) into the patient. After the measurement of a body part is taken with the device, the user can press the button 516 , causing the through-hole to press against the hollow member to prevent movement of the hollow member. This allows the user to remove the device from the patient to read the measurement scale while ensuring that movement of the measurement member 502 proximally or distally within the hollow member 504 is prevented. In FIG. 5 d , the measurement scale is read at point 526 on the handle when taking the measurement, for example.
[0067] During a measurement procedure, a user can hold syringe-style handle 506 with the dominant hand like a syringe, and can hold the barrel of the hollow member 504 with the non-dominant hand. After taking a measurement, the user can activate button 516 with the dominant or non-dominant hand to lock the measuring device, preventing the hollow member from sliding with respect to the measurement member.
[0068] Referring now to FIG. 6 a , another embodiment of a measuring device 600 is shown. Measuring device 600 includes many of the features of measuring device 100 , described above and illustrated in FIGS. 1 a - 1 e . For example, measuring device 600 includes an elongated measurement member 602 slidably disposed within an elongated hollow member 604 . Handle 606 can be positioned on a proximal portion of the measuring device, and measurement scale 608 , such as a color-coded measurement scale, can be disposed on the measurement member 602 . The measuring device can further include a flange 610 on a distal portion of the device, and an opening 612 that allows the measurement member 602 to extend distally beyond the hollow member 604 .
[0069] As described above, the device 600 can have a starting configuration, as shown in FIG. 6 b , and a measuring configuration, as shown in FIG. 6 c . The measuring device 600 can further include a locking mechanism 614 . The locking mechanism allows a user to lock the measurement member 602 within the hollow member 604 , to prevent movement of the measurement member with respect to the hollow member after a measurement is taken. In the embodiment shown in FIGS. 6 a - 6 f, the locking mechanism 614 is disposed on the hollow member 204 .
[0070] Referring now to FIG. 6 d , which is a cross sectional view of the locking mechanism 614 , the locking mechanism can further an annular snap 628 . The measurement member 602 also has an annular snap 630 that corresponds to the annular snap 628 on the locking mechanism. When the locking mechanism is in an unlocked configuration, as shown in FIG. 6 d , the annular snaps 628 and 630 are not in contact, so there is some play between the locking mechanism 614 and the measurement member 602 , which allows the measurement member to slide freely within the hollow member 604 . As a user rotates the locking mechanism, as shown in FIG. 6 e , the annular snaps contact each other, providing the user with tactile feedback of locking. In FIG. 6 f , the locking mechanism is shown in a locked configuration, with the annular snaps contacting each other on both sides. When the annular snaps are in contact as shown in FIG. 6 f , there is no play between the hollow member and the measurement member, which prevents movement of the hollow member with respect to the measurement member.
[0071] To take a measurement of a body part, a user can insert the measuring device 600 into the patient in the unlocked configuration. After the measurement of a body part is taken with the device, the user can rotate the locking mechanism 614 , causing the annular snaps to engage each other on both sides to lock the position of the measurement member 602 within the hollow member 604 . This allows the user to remove the device from the patient to read the measurement scale while ensuring that movement of the measurement member 602 proximally or distally within the hollow member 604 is prevented.
[0072] During a measurement procedure, a user can hold handle 606 with the dominant hand like a dart, and can hold the locking mechanism 614 with the non-dominant hand. After taking a measurement, the user can rotate the locking mechanism with the non-dominant hand until the annular snaps engage each other to lock the measuring device, preventing the hollow member from sliding with respect to the measurement member. The user can also hold steady the locking mechanism 614 with the non-dominant hand and rotate the handle 606 with the dominant hand until the annular snaps engage each other to lock the measuring device. The relative motion of the locking mechanism 614 and the handle 606 is what engages the locking mechanism, regardless of which is held in place and which is rotated.
[0073] Referring now to FIG. 7 a , another embodiment of a measuring device 700 is shown. Measuring device 700 includes many of the features of measuring device 100 , described above and illustrated in FIGS. 1 a - 1 e . For example, measuring device 700 includes an elongated measurement member 702 slidably disposed within an elongated hollow member 704 . The measuring device can further include a flange 710 on a distal portion of the elongated hollow member 704 , and an opening 712 that allows the measurement member 702 to extend distally beyond the hollow member 704 . Handle 706 can be positioned on a proximal portion of the measuring device and can be attached to the measurement member and measurement scale 708 can be disposed on the measurement member 702 . As shown in FIG. 7 f , the measurement scale can be a millimeter sale, with markings from 0-50 mm, marked in 5 mm increments. Moreover, the background 732 for the measurement scale 708 can be opaque. For example, the measurement member 702 can be composed of an opaque material or an opaque coating can cover the portion of the measurement member 702 on which the measurement scale 708 is printed. An opaque background for the measurement scale can allow for easier readability of the numbers on the scale. Further, the hollow member 704 can be transparent and include an indicator line 734 that is colored, e.g., blue, to help contrast it from the measurement scale. Contrasting the indicator line 734 with the measurement scale allows for easier readability of the final measurement.
[0074] As described above, the device 700 can have a starting configuration, as shown in FIG. 7 b , and a measuring configuration, as shown in FIG. 7 c . Similar to the embodiment of measuring device 400 described above and illustrated in FIGS. 4 a - 4 e, the hollow member 704 of the measuring device 700 in FIGS. 7 a - 7 d slides into the handle 706 (or, alternatively, the handle 706 slides over the hollow member 704 ) when a measurement is taken. The measurement member 702 remains fixed in position with respect to the handle, which allows the measurement member to extend distally beyond the flange 710 during measurements. As shown in FIGS. 7 g and 7 h , the elongated hollow member 704 can be free to rotate with respect to the handle 706 and the measurement member 702 ( FIG. 7 g shows the flange 710 extending parallel to the page, while FIG. 7 h shows the flange 710 extending out of the page). Such free rotation allows for the accommodation of any measurement technique, e.g. right or left-handed measurements, while still allowing for proper placement of the flange 710 . That is, rotation of the hollow member 702 to place the flange 710 in a desired position allows the measurement scale to remain in place, i.e., facing the user. Maintaining the measurement scale directed towards the users ensures that the user is more easily able to read and determine the measured length.
[0075] The measuring device 700 can further include a locking mechanism 714 . The locking mechanism allows a user to lock the hollow member 704 within the handle 706 , to prevent rotational or longitudinal movement of the hollow member with respect to the measurement member after a measurement is taken. In the embodiment shown in FIG. 7 d , the locking mechanism 714 can comprise a button 716 with a through-hole (not shown). Similar to the embodiments described above in FIGS. 4 a - 4 e, the device can have an unlocked configuration, in which the through-hole is aligned with the hollow member 704 to allow the hollow member to travel therethrough. The device can also have a locked configuration, in which the through-hole pushes against the hollow member thereby preventing movement of the hollow member with respect to the measurement member.
[0076] To take a measurement of a body part, a user can hold the handle 706 with the dominant hand and can hold the hollow member 704 with the non-dominant hand. The user can orient the measuring scale 708 such that it faces the user and can then rotate the hollow member 704 such that the flange 710 is properly oriented with respect to the patient. Because the hollow member 704 is transparent, the measuring scale 708 can be viewed through the hollow member 704 .
[0077] The measuring device 700 can be inserted in an unlocked configuration (e.g., where the through-hole is aligned to allowed movement of the hollow member) into the patient. After the measurement of a body part is taken with the device, as described above, the user can press the button 716 , causing the through-hole to press against the hollow member to prevent movement of the hollow member. This allows the user to remove the device from the patient to better read the measurement scale while ensuring that movement of the measurement member 702 proximally or distally within the hollow member 704 is prevented.
[0078] Referring to FIG. 8 , the devices described herein can be used to measure the vaginal cervical length. The flange 810 (representing any of the flanges described herein) can be placed against the proximal wall of cervix 802 , while the measurement member 702 (representing any of the measurement members described herein) can be extended along the lateral wall of the cervix 802 until it is stopped by the vaginal fornix 804 . The measurement member 702 and the flange 810 can then be locked with respect to one another such that the device's measurement scale can be used to determine the length as described above.
[0079] As for additional details pertinent to the present invention, materials and manufacturing techniques may be employed as within the level of those with skill in the relevant art. The same may hold true with respect to method-based aspects of the invention in terms of additional acts commonly or logically employed. Also, it is contemplated that any optional feature of the inventive variations described may be set forth and claimed independently, or in combination with any one or more of the features described herein. Likewise, reference to a singular item, includes the possibility that there are plural of the same items present. More specifically, as used herein and in the appended claims, the singular forms “a,” “and,” “said,” and “the” include plural referents unless the context clearly dictates otherwise. It is further noted that the claims may be drafted to exclude any optional element. As such, this statement is intended to serve as antecedent basis for use of such exclusive terminology as “solely,” “only” and the like in connection with the recitation of claim elements, or use of a “negative” limitation. Unless defined otherwise herein, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The breadth of the present invention is not to be limited by the subject specification, but rather only by the plain meaning of the claim terms employed. | A device for measuring a length of a cervix includes an elongate measurement member extending along a longitudinal axis and including a measurement scale thereon, a hollow member coaxial with and disposed over the elongate measurement member, a flange offset from the longitudinal axis and attached to a distal end of the hollow member, a handle attached to a proximal end of the measurement member, and a locking mechanism on the handle. The hollow member is freely rotatable about the longitudinal axis relative to the measurement member to place the flange in a first position and in a second position perpendicular to the first position without moving the measurement scale. The locking mechanism is configured, when locked, to fix the hollow member relative to the measurement member and, when unlocked, to allow the hollow member to slide axially along the measurement member in the first and second positions. | 51,890 |
This application is a division of application Ser. No. 12,504 filed Feb. 15, 1979, and now U.S. Pat. No. 4,215,146 which in turn is a division of application Ser. No. 825,535 filed Aug. 18, 1977, and now U.S. Pat. No. 4,166,132 of Aug. 28, 1979.
BACKGROUND OF THE INVENTION
Virus infections which attack mammals, including man, are normally contagious afflictions which are capable of causing great human suffering and economic loss. Unfortunately, the discovery of antiviral compounds is far more complicated and difficult than the discovery of antibacterial and antifungal agents. This is due, in part, to the close structural similarity of viruses and the structure of certain essential cellular components such as ribonucleic and deoxyribonucleic acids. Nevertheless, numerous non-viral "antiviral agents", i.e. substances "which can produce either a protective or therapeutic effect to the clear detectable advantage of the virus infected host, or any material that can significantly enhance antibody formation, improve antibody activity improve non-specific resistance, speed convalescence or depress symptoms" [Herrman et al., Proc. Soc. Exptl. Biol. Med., 103, 625 (1960)], have been described in the literature. The list of reported antiviral agents includes, to name a few, interferon and synthetic materials such as amantadine hydrochloride, pyrimidines, biguanides, guanidine, pteridines and methisazone. Because of the rather narrow range of viral infections that can be treated by each of the antiviral agents commercially available at the present time, new synthetic antiviral agents are always welcomed as potentially valuable additions to the armamentarium of medical technology.
The cells of mammals produce, in response to virus infection, a substance which enables cells to resist the multiplication of a variety of viruses. The viral-resisting or viral-interfering substances are referred to as "interferons". The interferons are glycoproteins which may differ in their physico-chemical properties, but all exhibit the same biological properties; namely, they inhibit a wide range of unrelated viruses, have no toxic or other deleterious effects on cells, and are species-specific (Lockart, Frontiers of Biology, Vol. 2, "Interferons", edited by Finter, W. B. Saunders Co., Philadephia, 1966, pages 19-20).
No practical, economical method has yet been developed for the preparation of exogenous interferon for routine clinical use against viral infections. An alternative approach to producing interferon has, therefore, been pursued, which comprises administering to the animal to be protected or treated a non-viral substance which stimulates--or induces--production of interferon in the cells. The interferon produced in this fashion is referred to as "endogenous" interferon.
U.S. Pat. No. 2,738,351 discloses that compounds of the general formula ##STR1## wherein each of R 1 and R 2 may be alkyl, aralkyl, aryl, cycloalkyl, nitro-substituted aryl, halogen-substituted aryl, alkyl-substituted aryl, or alkoxy-substituted aryl, each of X, Y and Z may be oxygen, sulfur or sulfonyl, ALK is straight or branched alkylene of from one to six carbon atoms, and B may be di(lower)alkylamino, piperidino, morpholino, pyrrolidino, (lower alkyl)pyrrolidino, N'-alkyl-piperazino or pipecolino, are local anesthetic agents. Additionally, the discussion of alternate synthetic routes (see Col. 1, 11. 57-70, of said patent) discloses intermediates of the above formula wherein B is amino and (lower alkyl)amino. However, none of the compounds specifically enumerate in the disclosure of said patent contain an alkyl R 1 or R 2 larger than n-pentyl. Furthermore, in none of these compounds are both R 1 and R 2 alkyl and both X and Y oxygen.
Insecticidal and miticidal compounds of the formula ##STR2## wherein R 1 and R 2 may each be, inter alia, lower alkylthio; q is 0 to 5; and A may be, inter alia, 1-piperidino or di(lower alkyl)amino are disclosed in Japanese Pat. No. J7-6042-177.
SUMMARY OF THE INVENTION
It has now been discovered that certain novel amine and amidine derivatives of di-O-(n-higher alkyl and alkenyl)-glycerols and -propanediols are capable of combating viral infections in mammals. The novel compounds of this invention have the formulae ##STR3## and the pharmaceutically acceptable acid addition salts thereof, wherein
R 1 and R 2 are each selected from the group consisting of normal alkyl of from 12 to 20 carbon atoms and normal alkenyl not having a double bond in the 1-position of from 12 to 20 carbon atoms,
Y is selected from the group consisting of alkylene of from 2 to 4 carbon atoms, the two valencies being on different carbon atoms; ##STR4## ortho-, meta- and para-phenylenedimethylene; ##STR5## wherein q is an integer of from one to three, and the left bond is connected to O; and ##STR6## wherein the left bond is connected to O,
Z is selected from the group consisting of alkylene of from 2 to 4 carbon atoms, the two valencies being on different carbon atoms; ortho-, meta- and para-phenylenedimethylene; ##STR7## wherein q is an integer of from one to three and the --(CH 2 ) q -- group is connected to --(CH 2 ) p NHR 3 ; and ##STR8## wherein the ##STR9## group is connected to --(CH 2 ) p NHR 3 ,
R 3 is selected from the group consisting of hydrogen, alkyl of from 2 to 4 carbon atoms and ω-hydroxy(normal alkyl) of from 2 to 4 carbon atoms,
m, n and p are each 0 or 1, the sum of m, n and p being 0 or 1, R 3 being hydrogen when m is 0, and R 3 being other than ω-hydroxy(normal alkyl) when m is 1 and Y is ##STR10##
W is selected from the group consisting of alkylene of from 1 to 4 carbon atoms, the two valencies being on different carbon atoms when W is other than methylene; ortho-, meta- and para-phenylene; and ##STR11## wherein the left bond is connected to O.
The invention disclosed herein comprises the novel antiviral compounds of formulae I to V, the novel pharmaceutical compositions containing an antivirally effective amount of a compound of formulae I to V as the essential active ingredient in a pharmaceutically acceptable carrier, the novel method of prophylactically controlling a viral infection in a mammal which comprises administering an amount effective to prophylactically control said viral infection of a compound of formulae I to V, and the novel method of inducing the production of interferon in a mammal which comprises administering an amount effective to induce the production of interferon of a compound of formulae I to V.
DETAILED DESCRIPTION OF THE INVENTION
The compounds of this invention exhibit antiviral activity against a wide variety of viruses in vivo in mammals and in virtro in mammalian tissue culture. At least a substantial portion of this activity results from the ability of said compounds to induce the production of interferon in the cells, i.e. endogenous interferon.
By "pharmaceutically acceptable" acid addition salts is meant those salts which are non-toxic at the dosages administered. The pharmaceutically acceptable acid addition salts which may be employed include such water-soluble and water-insoluble salts as the hydrochloride, hydrobromide, phosphate, nitrate, sulfate, acetate, hexafluorophosphate, citrate, gluconate, benzoate, propionate, butyrate, sulfosalicylate, maleate, laurate, malate, fumarate, succinate, oxalate, tartrate, amsonate (4,4'-diaminostilbene-2,2'-disulfonate), pamoate (1,1'-methylene-bis-2-hydroxy-3-naphthoate), stearate, 3-hydroxy-2-naphthoate, p-toluene sulfonate, methanesulfonate, lactate, and suramin salts.
One preferred group of the compounds of formulae I-V consists of the hydrochloride salts of the bases of formulae I-V.
Another preferred group of the compounds of formulae I-V consists of those wherein R 1 and R 2 are each normal alkyl of from 14 to 18 carbon atoms.
Another preferred group of the compounds of formulae I-V consists of those wherein R 1 and R 2 are each normal alkyl of from 14 to 18 carbon atoms and contain the same number of carbon atoms.
Another preferred group of the compounds of formulae I-V consists of those wherein R 1 and R 2 are each n-hexadecyl.
Another preferred group of the compounds of this invention consists of those of formula I.
Another preferred group of the compounds of this invention consists of those of formula II.
Another preferred group of the compounds of this invention consists of those of formula V.
One preferred group of the compounds of formulae I and II consists of those wherein m is 1, n is 0 p is 0, and R 3 is hydrogen.
Another preferred group of the comounds of formulae I and II consists of those wherein, m is 1, n is 0, p is 0, R 3 is hydrogen, and Y is straight chain alkylene of from 2 to 4 carbon atoms.
Another preferred group of the compounds of formulae I and II consists of those wherein m is 1, n is 0, p is 0, R 3 is hydrogen, and Y is ortho-, meta- or para-phenylenedimethylene.
Particularly valuable are the following compounds and their pharmaceutically acceptable acid addition salts:
1,3-di-O-(n-hexadecyl)-2-O-(3-aminopropyl)-glycerol,
1,2-di-O-(n-hexadecyl)-3-O-(3-aminopropyl)-glycerol,
1,3-di-O-(n-hexadecyl)-2-O-(meta-aminomethylbenzyl)-glycerol,
1,2-di-O-(n-hexadecyl)-3-O-(meta-aminomethylbenzyl)-glycerol,
1,2 -di-O-(n-tetradecyl)-3-O-(meta-aminomethylbenzyl)-glycerol,
1,3-di-O-(n-hexadecyl)-2-O-(meta-aminomethylphenyl)-glycerol,
1,3-di-O-(n-hexadecyl-2-O-(para-aminomethylphenyl)-glycerol,
1,2-di-O-(n-hexadecyl)-3-O-(para-aminomethylphenyl)-glycerol,
1,2-di(n-hexadecyloxy)-3-(meta-aminomethylbenzylamino)-propane,
1,2-di(n-hexadecyloxy)-3-aminomethyl-propane,
1,2-di-O-(n-hexadecyl)-3-O-(meta-amidinobenzyl)-glycerol,
1-[2,3-di(n-octadecyloxy)propyl]-4-aminomethyl-4-phenylpiperidine,
1-[2,3-di(n-hexadecyloxy)propyl]-4-aminomethyl-4-phenylpiperidine, and
1-[2,3-di(n-tetradecyloxy)propyl]-4-aminomethyl-4-phenylpiperidine.
The compounds of formulae I and II above may be prepared from the appropriate 1,2-di-O-(n-higher alkyl or alkenyl)-glycerol and 1,3-di-O-(n-higher alkyl or alkenyl)-glycerol starting materials by methods familiar to those skilled in the art. For example:
(a) those compounds wherein m is 1, R 3 is H and Y is 3-propylene may be prepared by condensing the starting material with acrylonitrile in aqueous solution under strongly basic conditions to form the 2-cyanoethyl derivative, which is then hydrogenated;
(b) those compounds wherein m is 1, R 3 is H and Y is 2-ethylene may be prepared by reacting the 2-cyanoethyl derivative of the starting material with formic acid under strongly acidic conditions to form the 2-carboxyethyl derivative, which is then reacted under strongly acidic conditions with hydrazoic acid;
(c) those compounds wherein m is 1, R 3 is H and Y is 4-butylene may be prepared by adding an allyl radical to the starting material by reacting it with an allyl halide under strongly basic conditions, hydroborating the allyl derivative, oxidizing the resulting intermediate with hydrogen peroxide in basic aqueous solution to the 3-hydroxypropyl derivative, reacting the 3-hydroxypropyl derivative with a sulfonyl chloride RSO 2 Cl (e.g. p-toluenesulfonyl chloride) under basic conditions to form the corresponding sulfonate ester (e.g. the tosylate), substituting a cyano group for the RSO 3 -- group by reaction with sodium cyanide, and then reducing the resulting 3-cyanopropyl derivative;
(d) those compounds wherein m is 1, R 3 is H and Y is 2-propylene may be prepared by following procedure (c) through the hydrogen peroxide oxidation step, isolating the 2-hydroxypropyl oxidation side product, and then subjecting the 2-hydroxypropyl derivative to the remainder of procedure (c) using sodium azide in place of sodium cyanide;
(e) those compounds wherein m is 1, R 3 is H and Y is 2-hydroxy-3-propylene may be prepared by oxidizing the allyl derivative of the starting material with a percarboxylic acid (e.g. m-chloroperbenzoic acid) to the 2,3-epoxypropyl derivative, and reacting the latter with sodium azide to form the 3-azido-2-hydroxypropyl derivative, which is then reduced;
(f) those compounds wherein m is 1, R 3 is H and Y is phenylenedimethylene may be prepared by reacting the starting material with a cyanobenzyl halide under strongly basic conditions, and then reducing the resulting cyanobenzyl derivative with a hydride reagent such as lithium aluminum hydride;
(g) those compounds wherein m is 1, R 3 is H, Y is ##STR12## and q is an integer of from one to three may be prepared by reacting the starting material with a sulfonyl chloride RSO 2 Cl (e.g. p-toluenesulfonyl chloride) under basic conditions to form the corresponding sulfonate ester (e.g. the tosylate) of di-O-(n-higher alkyl or alkenyl)-glycerol, substituting a cyanophenoxy or ω-cyanoalkylphenoxy group for the RSO 3 -- group by reaction with e.g. sodium cyanophenolate and then hydrogenating the resulting cyanophenyl or cyanoalkylphenyl derivative of the di-O-(n-higher alkyl or alkenyl)-glycerol starting material;
(h) those compounds wherein m is 1, R 3 is normal alkyl and Y is other than ##STR13## may be prepared by acylating the corresponding compound wherein R 3 is H with an acyl halide under basic conditions, and then reducing the resulting N-acyl derivative;
(i) those compounds wherein m is 1, R 3 is isopropyl and Y is other than ##STR14## may be prepared by reacting the corresponding compound wherein R 3 is H with acetone under acidic conditions and hydrogenating the resulting imine (e.g. with sodium borohydride);
(j) those compounds wherein m is 1, R 3 is other than H and Y is 2-ethylene may be prepared by oxidizing the allyl derivative of the di-O-(n-higher alkyl or alkenyl)-glycerol starting material by sequential treatment in the presence of water with osmium tetroxide (or potassium permanganate) and sodium periodate to the formylmethyl derivative, reacting the formylmethyl derivative with the amine R 3 NH 2 under acidic conditions, and hydrogenating the N-alkylidene or N-hydroxyalkylidene product;
(k) those compounds wherein m is 1, R 3 is alkyl and Y is ##STR15## may be prepared by reacting the 2,3-epoxypropyl derivative of the starting material with the amine R 3 NH 2 ;
(l) those compounds wherein P is 1 may be prepared by reacting a sulfonate ester (e.g. the tosylate) of the appropriate di-O-(n-higher alkyl or alkenyl)-glycerol [prepared from the starting material as in (g)] with sodium cyanide, and then hydrogenating the resulting cyano derivative of di(n-higher alkyloxy or alkenyloxy)propane;
(m) those compounds wherein m, n and p are all 0 may be prepared as in (l) using sodium azide in place of sodium cyanide;
(n) those compounds wherein n is 1 and Z is 3-propylene may be prepared by condensing the corresponding compound wherein m, n and p are all 0 with acrylonitrile in aqueous solution under strongly basic conditions to form the N-(2-cyanoethyl)-amino derivative of di(n-higher alkyloxy or alkenyloxy)propane, which is then hydrogenated;
(o) those compounds wherein n is 1 and Z is phenylenedimethylene may be prepared by reacting a xylylenediamine with a sulfonate ester (e.g. the tosylate) of the appropriate di-O-(n-higher alkyl or alkenyl)-glycerol; and
(p) those compounds wherein m is 1, R 3 is alkyl and Y is ##STR16## may be prepared by reducing a cyanobenzyl derivative of the di-O-(n-higher alkyl or alkenyl)-glycerol starting material to the formylbenzyl derivative, reducing the formylbenzyl derivative in the presence of trimethylsulfonium iodide to the 1,2-epoxyethylbenzyl derivative, and then reacting the latter derivative with the amine R 3 NH 2 .
The skilled worker in the art will realize that additional compounds of formulae I and II may be prepared by using obvious variations of the methods of synthesis outlined above.
The compounds of formulae III and IV above may also be prepared from the appropriate 1,2-di-O-(n-higher alkyl or alkenyl)-glycerol and 1,3-di-O-(n-higher alkyl or alkenyl)-glycerol starting material by methods familiar to those skilled in the art. For example, those compounds wherein W is phenylene may be prepared by condensing a cyanophenyl derivative of the starting material with ethanol or ethanethiol in a hydrogen chloride saturated inert solvent such as dioxane to form the corresponding ethylbenzimidate or ethylthiobenzimidate hydrochloride, followed by nucleophilic substitution with ammonia and elimination of ethanol or ethanethiol which is carried out in ammonia saturated ethanol. Those compounds wherein W is ##STR17## may be prepared in like manner from a cyanobenzyl derivative of the starting material. Those compounds where W is alkylene may be prepared in like manner from the appropriate cyano (lower alkyl) derivative of the starting material. When W is methylene, said derivative may be prepared by reacting the starting material with chloro-, bromo-, or iodoacetonitrile.
The compounds of formula V above may be prepared from the appropriate 1,2-di-O-(n-higher alkyl or alkenyl)-glycerol starting materials by methods familiar to those skilled in the art. For example, the tosyl derivative of the starting material may be reacted with 4-cyano-4-phenylpiperidine hydrochloride, and the resulting compound then reduced.
Acid addition salts of the bases of formulae I-V may be prepared by conventional procedures such as by mixing the amine or amidine compound in a suitable solvent with the required acid and recovering the salt by evaporation or by precipitation upon adding a non-solvent for the salt. Hydrochloride salts may readily be prepared by passing hydrogen chloride through a solution of the amine or amidine compound in an organic solvent. As can be seen by reference to the examples herein, many of the isolated hydrochloride or dihydrochloride salts of the bases of formulae I-V tend to contain a significant water content. Whether this observed "trapped" water is randomly occluded during crystallization, or corresponds to formation of true molecular hydrates, or results from the occurrence of some other phenomenon, is not known. In any event, the salts containing "trapped" water may be efficaciously formulated and administered without preliminary dehydration.
The 1,2-di-O-(n-higher alkyl)-glycerol starting materials may be prepared by the method of Kates, M. et al., Biochemistry, 2, 394 (1963). The 1,3-di-O-(n-higher alkyl)-glycerol starting materials may be prepared by the method of Damico, R., et al., J. Lipid Res., 8, 63, (1967). The 1,2- and 1,3-di-O-(n-higher alkenyl)-glycerol starting materials may be prepared by the method of Bauman, W. J. and Mangold, H. K., J. Org. Chem., 31, 498 (1966).
The antiviral activity of the compounds of this invention was determined by the use of two independent procedures. In the first, the test compound is administered to mice by the intraperitoneal route eighteen to twenty-four hours prior to challenging them with a lethal dose of encephalomyocarditis (EMC) virus. Survival data are taken during the ten days after challenge and compared with the data for unprotected animals. The procedure in which the drug is given eighteen to twenty-four hours before, and at a distinctly different site from, virus injection is designed to eliminate local effects between drug and virus and identify only those compounds which produce a systemic antiviral response.
In the second procedure, monolayers of human nasal polyp cells grown on microtiter plates are treated with the test compound about eighteen hours before treatment with a lethal dose of vesicular stomatitus virus (VSV). The test compound is washed away from the monolayers before virus treatment. Culture fluid extracted from the plates after a post challenge incubation period is titrated for the amount of infectious virus present in microtite plates of L-929 mouse fibroblasts. Comparison is made with the virus yield data for culture fluid extracted from unprotected polyp cells.
Additionally, many of the compounds of this invention were tested for their ability to enhance the known antiviral activity of polyinosinic:polycytidylic acid. Finally, certain of the compounds were also tested for their ability to induce circulating interferon in mice after parenteral administration, using the procedure described by Hoffman, W. W., et al., Antimicrobial Agents and Chemotherapy, 3, 498-501 (1973).
Parenteral, topical or intranasal administration of the above-described amines and amidines to a mammal before exposure of the mammal to an infectious virus provides rapid resistance to the virus. Preferably, administration should take place from about two days to about one day before exposure to the virus, although this will vary somewhat with the particular animal species and the particular infectious virus.
When the materials of this invention are administered, they are most easily and economically used in a dispersed form in an acceptable carrier. When it is said that this material is dispersed, it means that the particles may be molecular in size and held in true solution in a suitable solvent or that the particles may be colloidal in size and dispersed through a liquid phase in the form of a suspension or an emulsion. The term "dispersed" also means that the particles may be mixed with and spread throughout a solid carrier so that the mixture is in the form of a powder or dust. This term is also meant to encompass mixtures which are suitable for use as sprays, including solutions, suspensions or emulsions of the agents of this invention.
When administered parenterally (subcutaneously, intramuscularly, intraperitoneally) the materials of this invention are used at a level of from about 1 mg./kg. of body weight to about 250 mg./kg. body weight. The favored range is from about 5 mg./kg. to about 100 mg./kg. of body weight, and the preferred range from about 5 mg. to about 50 mg./kg. of body weight. The dosage, of course, is dependent upon the mammal being treated and the particular amine or amidine compound involved and is to be determined by the individual responsible for its administration. Generally, small doses will be administered initially with gradual increase in dosage until the optimal dosage level is determined for the particular subject under treatment.
Vehicles suitable for parenteral injection may be either aqueous such as water, isotonic saline, isotonic dextrose, Ringer's solution, or non-aqueous such as fatty oils of vegetable origin (cottonseed, peanut oil, corn, sesame) and other non-aqueous vehicles which will not interfere with the efficacy of the preparation and are non-toxic in the volume or proportion used (glycerol, ethanol, propylene glycol, sorbitol). Additionally, compositions suitable for extemporaneous preparation of solutions prior to administration may advantageously be made. Such compositions may include liquid diluents, for example, propylene glycol, diethyl carbonate, glycerol, sorbitol.
In practicing the intranasal route of administration of this invention any practical method can be used to contact the antiviral agent with the respiratory tract of the mammal. Effective methods include administration of the agent by intranasal or nasopharyngeal drops and by inhalation as delivered by a nebulizer or an aerosol. Such methods of administration are of practical importance because they provide an easy, safe and efficient method of practicing this invention. For intranasal administration of the agent, usually in an acceptable carrier, a concentration of agent between 1.0 mg./ml. and 100 mg./ml. is satisfactory. Concentrations in the range of about 30 to 50 mg./ml. allow administration of a convenient volume of material.
For topical application the antiviral agents are most conveniently used in an acceptable carrier to permit ease and control of application and better absorption. Here also concentrations in the range of from about 1.0 mg./ml. to about 250 mg./ml. are satisfactory. In general, in the above two methods of administration a dose within the range of about 1.0 mg./kg. to about 250 mg./kg. of body weight and, preferably, from about 5.0 mg./kg. to about 50 mg./kg. of body weight will be administered.
The compounds employed in this invention may be employed alone, i.e., without other medicinals, as mixtures of more than one of the herein-described compounds, or in combination with other medicinal agents, such as analgesics, anesthetics, antiseptics, decongestants, antibiotics, vaccines, buffering agents and inorganic salts, to afford desirable pharmacological properties. Further, they may be administered in combination with hyaluronidase to avoid or, at least, to minimize local irritation and to increase the rate of absorption of the compound. Hyaluronidase levels of at least about 150 (U.S.P.) units are effective in this respect although higher or lower levels can, of course, be used.
Those materials of this invention which are water-insoluble, including those which are of low and/or difficult solubility in water, are, for optimum results, administered in formulations, e.g., suspensions, emulsions, which permit formation of particle sizes of less than about 20μ. The particle sizes of the formulations influence their biological activity apparently through better absorption of the active materials. In formulating these materials various surface active agents and protective colloids are used. Suitable surface active agents are the partial esters of common fatty acids, such as lauric, oleic, stearic, with hexitol anhydrides derived from sorbitol, and the polyoxyethylene derivatives of such ester products. Such products are sold under the trademarks "Spans" and "Tweens," respectively, and are available from ICI United States Inc., Wilmington, Del. Cellulose ethers, especially cellulose methyl ether (Methocel, available from the Dow Chemical Co., Midland, Mich.) are highly efficient as protective colloids for use in emulsions containing the materials of this invention.
The water-soluble materials described herein are administered for optimum results in aqueous solution. Typically they are administered in phosphate buffered saline. The water-insoluble compounds are administered in formulations of the type described above or in various other formulations as previously noted. Dimethylsulfoxide serves as a suitable vehicle for water-insoluble compounds. A representative formulation for such compounds comprises formulating 25 to 100 mg. of the chosen drug as en emulsion by melting and mixing with equal parts of polysorbate 80 and glycerin to which hot (80° C.) water is added under vigorous mixing. Sodium chloride is added in a concentrated solution to a final concentration of 0.14 M and sodium phosphate, pH 7, is added to a final concentration of 0.01 M to give, for example, the following representative composition:
______________________________________ mg./ml.______________________________________Drug 50.0Polysorbate 80 50.0Glycerin 50.0Sodium Phosphate Monobasic Hydrous 1.4Sodium Chloride 7.9Water 842.0 1001.3______________________________________
In certain instances, as where clumping of the drug particles occurs, sonication is employed to provide a homogeneous system.
The following examples illustrate the invention but are not to be construed as limiting the same.
EXAMPLE 1
1,3-Di-O-(n-hexadecyl)-2-O-(3-aminopropyl)-glycerol Hydrochloride
A. 1,3-Di-O-(n-hexadecyl)-2-O-(2-cyanoethyl)-glycerol
A mixture of 1,3-di-O-(n-hexadecyl)-glycerol (80 g., 148 mmoles), acrylonitrile (1.49 kg., 28.1 moles) and aqueous 2 N sodium hydroxide (1.2 l.) was heated to 50° C. Tetrabutylammonium hydroxide (19.2 g. of 40 wt. % aqueous solution, 29.15 mmoles) was slowly added, causing the temperature of the exothermic reaction mixture to rise to about 80° to 90° C. The reaction mixture was then stirred for 20 minutes without any external heating, followed by cooling to 20° C. and addition of water (1.0 l.). A solid material, a mixture of unreacted and cyanoethylated 1,3-di-O-(n-hexadecyl)-glycerol, was isolated and treated again with fresh acrylonitrile (1.49 kg., 28.1 moles), aqueous 2 N sodium hydroxide (1.2 l.) and tetrabutylammonium hydroxide (19.2 g. of 40 wt. % aqueous solution, 29.15 mmoles) for 20 minutes with stirring at 50° C., followed by cooling and addition of water (1.0 l.). The resulting 1,3-di-O-(n-hexadecyl)-2-O-(2-cyanoethyl)-glycerol solids were filtered, washed consecutively with water, methanol and acetonitrile, and dried [82 g., 93% yield, m.p. 45°-46° C., ir (CHCl 3 ) 2250 cm -1 , n.m.r. (CDCl 3 ) δ 3.92 (t, 2, NCCH 2 CH 2 O--), 3.33-3.67 (m, 9, --OCH[CH 2 OCH 2 C 15 H 31 ] 2 ), 2.62 (t, 2, NCCH 2 CH 2 O--) and 0.75-1.58 (m, 62, aliphatic protons)].
B. Title Compound
A mixture of 1,3-di-O-(n-hexadecyl)-2-O-(2-cyanoethyl)-glycerol (20.5 g., 34.5 mmoles), tetrahydrofuran (200 ml.), ethanol (10 ml.) and Raney nickel catalyst (3 g.) was saturated with ammonia gas at 0° to 5° C. and then hydrogenated (50 psi) in a Paar hydrogenator for 3 hours at room temperature. The mixture was then filtered, the catalyst washed with tetrahydrofuran (50 ml.), and the total filtrate evaporated in vacuo to an oil. This procedure was repeated three more times with fresh reactants and catalyst to yield a total of 77 g. of oil. The oil was dissolved in ether (500 ml.) and the solution washed with 2 wt. % aqueous ammonium hydroxide solution (500 ml.), dried (MgSO 4 ), filtered and evaporated in vacuo to yield a solid. The solid was dissolved in methanol (300 ml.) and the solution saturated with hydrogen chloride gas and then evaporated in vacuo to a solid. This solid was crystallized from ethyl acetate to yield the named product with a slight impurity (63 g., 72% yield, m.p. 69°-70° C.), and then recrystallized twice from isopropanol:acetonitrile (1:1, 800 ml.) [47.5 g., 54% yield, m.p. 58°-59° C., n.m.r. (CDCl 3 ) δ 3.84 (t, 2, H 2 NCH 2 CH 2 CH 2 O--), 3.55 (m, 9, --OCH[CH 2 OCH 2 C 15 H 31 ] 2 ), 3.24 (t, 2, H 2 NCH 2 CH 2 CH 2 O--), 2.04 (m, 2, H 2 NCH 2 CH 2 CH 2 O--) and 0.90-1.32 (m, 62, aliphatic protons), elemental analysis calculated: 72.04% C; 12.73% H; 2.21% N; found: 71.80% C; 12.41% H; 2.30% N].
EXAMPLES 2-7
In like manner to that described in Example 1 the following compounds were prepared by using the appropriate 1,3- or 1,2-di-O-(n-higher alkyl)-glycerol as starting material: ##STR18##
__________________________________________________________________________ Elemental AnalysisExample Molecular Calculated Found (%)NumberStructure R.sub.1 R.sub.2 Formula M.P. (° C.) C H N C H N__________________________________________________________________________2 I n-dodecyl n-dodecyl C.sub.30 H.sub.63 O.sub.3 N . HCl . 3/2H.sub.2 76-77 65.60 12.29 2.54 65.45 11.91 2.613 I n-tetradecyl n-tetradecyl C.sub.34 H.sub.71 O.sub.3 N . HCl . H.sub.2 57-58 68.47 12.50 2.35 68.51 11.24 2.294 I n-octadecyl n-octadecyl C.sub.42 H.sub.87 O.sub.3 N . HCl 64-65 73.04 12.84 2.03 72.96 12.56 1.995 II n-tetradecyl n-tetradecyl C.sub.34 H.sub.71 O.sub.3 N . HCl 90-91 70.60 12.55 2.42 70.74 12.85 2.686 II n-hexadecyl n-hexadecyl C.sub.38 H.sub.79 O.sub.3 N . HCl . 3/4H.sub.2 76-78 70.54 12.77 2.16 70.42 12.17 2.077 II n-octadecyl n-octadecyl C.sub.42 H.sub.87 O.sub.3 N . HCl . H.sub.2 67-69 71.19 12.80 1.98 70.95 12.19 1.91__________________________________________________________________________
EXAMPLE 8
1,3-Di-O-(n-hexadecyl)-2-O-(2-aminoethyl)-glycerol Hydrochloride
A. 1,3-di-O-(n-hexadecyl)-2-O-(2-carboxyethyl)-glycerol
A mixture of 1,3-di-O-(n-hexadecyl)-2-O-(2-cyanoethyl)-glycerol (4.8 g., 8.1 mmoles), concentrated hydrochloric acid (50 ml.) and formic acid (50 ml.) was stirred for 16 hours at reflux, then cooled and extracted with ether (3×100 ml.). The combined ether extract was washed with water (200 ml.), dried (MgSO 4 ), filtered and evaporated in vacuo to yield 1,3-di-O-(n-hexadecyl)-2-O-(2-carboxyethyl)-glycerol solids (4.5 g.), which were purified by silica gel chromatography (elution with toluene:ethanol) [3.5 g., 71% yield, m.p. 43°-45° C., ir (CHCl 3 ) 1740 cm -1 , n.m.r. (CDCl 3 ) δ 3.93 (t, J=6 Hz, 2, --OCH 2 CH 2 COOH) and 2.65 (t, J=6 Hz, 2, --OCH 2 CH 2 COOH)].
B. Title Compound
1,3-Di-O-(n-hexadecyl)-2-O-(2-carboxyethtyl)-glycerol (3.5 g., 5.7 mmoles) was dissolved in a mixture of benzene (55 ml.) and concentrated sulfuric acid (5.89 g.). Hydrazoic acid (6.34 ml. of 4.65 wt. % benzene solution, 6.0 mmoles) was then added dropwise and the resulting mixture stirred for 2 hours at room temperature. Thin layer chromatography (TLC) analysis showed about 50% reaction of the 2-carboxyethyl compound. Additional hydrazoic acid (6.34 ml. of 4.65 wt. % benzene solution, 6.0 mmoles) was added dropwise and the reaction mixture stirred for another 16 hours at 40° C. TLC analysis now showed that the reaction was essentially complete. Water (50 ml.) and aqueous 2 N sodium hydroxide were then added and the resulting mixture extracted with ether (3×200 ml.). The combined ether extract was dried (Na 2 SO 4 ), filtered, saturated with hydrogen chloride gas and evaporated in vacuo to yield a solid. The solid was purified by silica gel chromatography (elution with chloroform:methanol) and recrystallized from hot ethyl acetate [570 mg., 16% yield, m.p. 79°-80° C., n.m.r. (CDCl 3 ) δ 3.95 (m, 2, --OCH 2 CH 2 NH 2 ) and 3.22 (m, 2, --OCH 2 CH 2 NH 2 ), elemental analysis calculated: 71.62% C; 12.67% H; 2.26% N; found: 70.90% C; 12.19% H; 2.05% N].
EXAMPLE 9
1,3-Di-O-(n-hexadecyl)-2-O-(3-ethylaminopropyl)-glycerol Hydrochloride
A. 1,3-Di-O-(n-hexadecyl)-2-O-(3-acetamidopropyl)-glycerol
1,3-Di-O-(n-hexadecyl)-2-O-(3-aminopropyl)-glycerol hydrochloride (1.0 g., 1.6 mmoles) was added to a mixture of potassium carbonate (830 mg., 6.0 mmoles) and benzene (75 ml.). Acetyl chloride (150 mg., 1.9 mmoles) was then added and the resulting mixture stirred for one hour at reflux. Additional acetyl chloride (150 mg., 1.9 moles) was added and the reaction mixture stirred for another hour at reflux. TLC analysis showed that the reaction was essentially complete. The reaction mixture was cooled, water (75 ml.) added, and the resulting mixture extracted with ether (3×100 ml.). The combined ether extract was dried (MgSO 4 ), filtered and evaporated in vacuo to yield the named compound [800 mg., 79% yield, m.p. 53°-54° C., ir (CHCl 3 ) 3400 and 1670 cm -1 , n.m.r. (CDCl 3 ) δ 1.97 (s, 3, --NHCOCH 3 )].
B. Title Compound
1,3-Di-O-(n-hexadecyl)-2-O-(3-acetamidopropyl)-glycerol (700 mg., 1.1 mmoles) was dissolved in ether (100 ml.) and treated with lithium aluminum hydride (500 mg., 13 mmoles). Water (100 ml.) was then added and the mixture extracted with ether (2×100 ml). The combined ether extract was dried (MgSO 4 ), filtered, treated with hydrogen chloride gas and evaporated in vacuo to a solid, which was recrystallized from hot ethyl acetate [470 mg., 66% yield, m.p. 61°-62° C., n.m.r. (CDCl 3 ) δ 1.47 (t, 3, --NHCH 2 CH 3 ), elemental analysis calculated: 72.51% C; 12.78% H; 2.11% N; found: 72.47% C; 12.56% H; 2.03% N].
EXAMPLE 10
1,3-Di-O-(n-hexadecyl)-2-O-(3-isopropylaminopropyl)-glycerol Hydrochloride
1,3-Di-O-(n-hexadecyl)-2-O-(3-aminopropyl)-glycerol hydrochloride (700 mg., 1.1 mmoles) was dissolved in a solution of acetic acid (1.05 ml.), sodium acetate (350 mg., 4.3 mmoles) and acetone (1.3 ml.). Sodium borohydride (1.25 g., 33 mmoles) was added in small portions until TLC analysis showed that all the 3-aminopropyl compound had been consumed. The reaction mixture was then treated with aqueous 2 N sodium hydroxide (20 ml.) and water (20 ml.), and extracted with ether (3×40 ml.). The combined ether extract was dried (MgSO 4 ), filtered, treated with hydrogen chloride gas, and then evaporated in vacuo to a solid, which was recrystallized from hot ethyl acetate [210 mg., solid contained about 1/2 mole H 2 O per mole named product, 28% yield, m.p. 72°-73° C., n.m.r. (CDCl 3 ) δ 1.42 (d, 6, --NHCH[CH 3 ] 2 ), elemental analysis calculated: 71.82% C; 12.79% H; 2.04% N; found: 71.92% C; 12.46% H; 1.94% N].
EXAMPLE 11
1,2-Di-O-(n-hexadecyl)-3-O-(2-isopropylaminoethyl)-glycerol Hydrochloride
A. 1,2-Di-O-(n-hexadecyl)-3-O-allyl-glycerol
Sodium hydride (1.78 g. of 50 wt. % dispersion in mineral oil, 37 mmoles) was added at 60° C. to a solution of 1,2-di-O-(n-hexadecyl)-glycerol (10 g., 18.5 mmoles) in N,N-dimethylformamide (100 ml.), and the resulting solution stirred for 20 minutes at 60° C. Allyl bromide (4.47 g., 37 mmoles) was then added dropwise and the resulting mixture stirred for 3 hours at 90° C., cooled, cautiosly diluted with water (200 ml.) to quench the reaction, and extracted with ether (3×150 ml.). The combined ether extract was washed with saturated aqueous sodium chloride solution, dried (MgSO 4 ), filtered and evaporated in vacuo to an oil, which was purified by silica gel chromatography (elution with benzene) [10 g., 93% yield, oil, n.m.r. (CDCl 3 ) δ 5.66-6.16 (m, 1, --OCH 2 CH═CH 2 ), 5.25 (d of doublets, 2, --OCH 2 CH═CH 2 ) and 4.03 (d, 2, --OCH 2 CH═CH 2 )].
B. 1,2-Di-O-(n-hexadecyl)-3-O-formylmethyl-glycerol
Osmium tetraoxide (90 mg., 0.354 mmoles) was added to a solution of 1,2-di-O-(n-hexyadecyl)-3-O-allyl-glycerol (4.5 g., 7.75 mmoles) in tetrahydrofuran:water (3:1, 120 ml.), and the resulting solution stirred for 5 minutes at room temperature. Sodium periodate (9 g., 42 mmoles) was then added and the reaction solution stirred for 16 hours at room temperature under nitrogen. The reaction solution was then diluted with water (150 ml.) and extracted with ether (2×150 ml.). The combined ether extract was washed with water (150 ml.), dried (MgSO 4 ) and evaporated in vacuo to an oil, which was purified by silica gel chromatography (elution with benzene:ethyl acetate) [2.6 g., 57% yield, waxy solid, ir (CHCl 3 ) 1735 cm -1 , n.m.r. (CDCl 3 ) δ 9.38 (t, J=1 Hz, 1, --OCH 2 CHO) and 4.07 (d, J=1 Hz, 2, --OCH 2 CHO)].
C. Title Compound
Sodium cyanoborohydride (0.1 g., 1.6 mmoles) was added to a solution of 1,2-di-O-(n-hexadecyl)-3-O-formylmethyl-glycerol (1.5 g., 2.6 mmoles) and isopropylamine (0.89 g., 15 mmoles) in methanol:tetrahydrofuran (1:1, 50 ml.), and the mixture stirred for two hours at room temperature. The pH was then adjusted to 6 with 5 N methanolic hydrochloric acid, additional sodium cyanoborohydride (0.1 g., 1.6 mmoles) added, and the reaction mixture then stirred for another 60 hours at room temperature, filtered, treated with aqueous 3 N sodium hydroxide (10 ml.) and saturated aqueous sodium chloride solution (200 ml.), and extracted with ether (2×150 ml.). The combined ether extract was dried (MgSO 4 ), filtered and evaporated in vacuo to an oily solid, which was purified by silica gel chromatography (elution with benzene:ethanol) and dissolved in methanol. The solution was treated with hydrogen chloride gas and evaporated in vacuo to yield a solid, which was recrystallized from ethyl acetate [400 mg., solid contained about 1/4 mole H.sub. 2 O per mole named product, 23% yield, m.p. 71°-72° C., n.m.r. (CDCl 3 ) δ 1.42 (d, J=6 Hz, 6, --NHCH[CH 3 ] 2 ), elemental analysis calculated: 72.02% C; 12.76% H; 2.10% N; found: 71.89% C; 12.34% H; 2.09% N].
EXAMPLE 12
1,2-Di-O-(n-hexadecyl)-3-O-[2-(2-hydroxyethylamino)ethyl]-glycerol Hydrochloride
In like manner to that described in Example 11 the named compound was prepared by reacting 2-hydroxyethylamine with 1,2-di-O-(n-hexadecyl)-3-O-formylmethyl-glycerol [solid contained about 1/2 mole H 2 O per mole named product, m.p. 125°-126° C., elemental analysis calculated: 69.54% C; 12.42% H; 2.07% N; found: 69.62% C; 12.08% H; 2.29% N].
EXAMPLE 13
1,3-Di-O-(n-hexadecyl)-2-O-(4-aminobutyl)-glycerol Hydrochloride
A. 1,3-Di-O-(n-hexadecyl)-2-O-(3-hydroxypropyl)-glycerol
Borane methyl sulfide (BMS) complex (6.5 ml., 68.5 mmoles) was added at 0° to 5° C. to a solution of 1,3-di-O-(n-hexadecyl)-2-O-allyl-glycerol (10.82 g., 18.6 mmoles, prepared as in Example 11A) in hexane (190 ml.), and the resulting solution stirred for 3 hours at room temperature. The reaction solution was then cooled again to 0° to 5° C. and ethanol (17.3 ml.) added dropwise to decompose residual BMS. The reaction solution was then treated with aqueous 3 N sodium hydroxide (13 ml.) and 30 wt. % aqueous hydrogen peroxide (11 ml.), stirred for 16 hours at reflux, cooled, and poured into ice water containing sodium bisulfite. The ice water solution was stirred until it gave a negative starch-iodide test for peroxides, and then extracted with ether (3×200 ml.). The combined ether extract was washed with water (200 ml.), washed with saturated aqueous sodium chloride solution (200 ml.), dried (MgSO 4 ), filtered and evaporated in vacuo. The resulting product was purified by silica gel chromatography (elution with benzene:ethanol) [5 g., 45% yield, m.p. 29° C., n.m.r. (CDCl 3 ) δ 3.80 (t, J=5 Hz, 2, --OCH 2 CH 2 CH 2 OH) and 3.75 (t, J=5 Hz, 2, --OCH 2 CH 2 CH 2 OH)].
B. 1,3-Di-O-(n-hexadecyl)-2-O-[3-(p-tosyloxy)propyl]-glycerol
1,3-Di-O-(n-hexadecyl)-2-O-(3-hydryoxypropyl)-glycerol (8.0 g., 13.4 mmoles) was added at 10° C. to a solution of p-toluenesulfonyl chloride (5.25 g., 27.5 mmoles) and pyridine (10 ml) in methylene chloride (200 ml.), and the mixture stirred for 60 hours at room temperature. Water (200 ml.) was then added, the methylene chloride and aqueous phases separated, and the latter extracted with methylene chloride (2×150 ml.). The three methylene chloride layers were combined, washed with water (2×150 ml.), dried (MgSO 4 ), filtered and evaporated in vacuo. The resulting tosylate was purified by silica gel chromatography (elution with benzene) [3.0 g., 30% yield, oil, ir (CHCl 3 ) 1130 and 1350 cm -1 , n.m.r. (CDCl 3 ) δ 7.53 (q, 4 protons on phenyl ring), 4.15 (t, 2, --SO 3 CH 2 CH 2 CH 2 O--), 3.63 (t, 2, --SO 3 CH 2 CH 2 CH 2 O--), 3.42 (m, 9, --OCH[CH 2 OCH 2 C 15 H 31 ] 2 ), 2.45 (s, 3, Ar-CH 3 ), 1.90 (m, 2, --SO 3 CH 2 CH 2 CH 2 O--) and 0.90-1.50 (m, 62, aliphatic protons)].
C. 1,3-Di-O-(n-hexadecyl)-2 -O-(3-cyanopropyl)-glycerol
1,3-Di-O-(n-hexadecyl)-2-O-[3-(p-tosyloxy)propyl]-glycerol (3.0 g., 4.0 mmoles) was dissolved in a solution of sodium cyanide (0.5 g., 10 mmoles) in N,N-dimethylformamide (50 ml.), and the resulting solution stirred for 16 hours at 80° C., cooled, diluted with water (100 ml.) and extracted with ether (3×100 ml.) The combined ether extract was washed consecutively with 1 N hydrochloric acid (3×75 ml.), saturated aqueous sodium bicarbonate solution (3×75 ml.), water (75 ml.) and saturated aqueous sodium chloride solution (75 ml.), then dried (MgSO 4 ), filtered and evaporated in vacuo to yield a waxy solid that was used in the next step without further purification [2.0 g., 83% yield, ir (CHCl 3 ) 2250 cm -1 ].
D. Title Compound
Lithium aluminum hydride (800 mg., 21 mmoles) was added to a solution of 1,3-di-O-(n-hexadecyl)-2-O-(3-cyanopropyl)-glycerol (2.0 g., 3.3 mmoles) in ether (100 ml.), and the mixture stirred for 60 hours at room temperature. Enough water to quench the reaction was added cautiously, followed by an additional 100 ml. of water. The resulting mixture was stirred for another hour at room temperature and then extracted with ether (3×100 ml.). The combined ether extract was washed with saturated aqueous sodium chloride solution (3×75 ml.), dried (MgSO 4 ), filtered and evaporated in vacuo to an oil, which was purified by silica gel chromatography (elution with benzene:ethanol) and then dissolved in ethanol. The solution was treated with hydrogen chloride gas and then evaporated in vacuo to yield a solid, which was recrystallized from ethyl acetate [444 mg., 21% yield, m.p. 61.5°-63.5° C., n.m.r. (CDCl 3 ) δ 3.67 (t, 2, --OCH 2 CH 2 CH 2 CH 2 NH 2 ), 3.55 (m, 9, --OCH[CH 2 OCH 2 C 15 H 31 ] 2 ), 3.10 (t, 2, --OCH 2 CH 2 CH 2 CH 2 NH 2 ), 1.50-2.00 (m, 4, --OCH 2 CH 2 CH 2 CH 2 NH 2 ) and 0.80-1.50 (m, 62, aliphatic protons), elemental analysis calculated: 72.23% C; 12.74% H; 2.16% N; found: 72.53% C; 12.42% H; 2.10% N].
EXAMPLE 14
1,2-Di-O-(n-hexadecyl)-3-O-(3-aminomethylbenzyl)-glycerol Hydrochloride
A. 1,2-Di-O-(n-hexadecyl)-3-O-(3-cyanobenzyl)-glycerol
Sodium hydride (1.056 g. of 50 wt. % mineral oil dispersion, 22 mmoles) was added to a solution of 1,2-di-O-(n-hexadecyl)-glycerol (9.73 g., 18 mmoles) in tetrahydrofuran (150 ml.) and the resulting solution stirred for 20 minutes at room temperature under nitrogen. m-Cyanobenzyl bromide (4.0 g., 20 mmoles) was added and the reaction mixture stirred overnight at room temperature under nitrogen. Water (200 ml.) was then added cautiously and the resulting mixture extracted with ethyl acetate (3×150 ml.). The combined ethyl acetate extract was dried (MgSO 4 ), filtered and evaporated in vacuo to an oil (12 g.), which was purified by silica gel chromatography (elution with benzene:hexane) [8.0 g., 68% yield, oil, ir (CHCl 3 ) 2230 cm -1 ].
B. Title Compound
A solution of 1,2-di-O-(n-hexadecyl)-3-O-(3-cyanobenzyl)-glycerol (1.0 g., 1.5 mmoles) in ether (10 ml.) was slowly added under nitrogen to a suspension of lithium aluminum hydride (0.057 g., 1.5 mmoles) in ether (40 ml.), and the resulting mixture stirred for one hour at reflux under nitrogen and then cooled. Water (50 ml.) was added cautiously and the mixture extracted with ether (3×50 ml.). The combined ether extract was dried (MgSO 4 ), filtered and evaporated in vacuo to an oil, which was purified by silica gel chromatography (elution with benzene:ethanol) and then dissolved in ethyl acetate. The solution was treated with hydrogen chloride gas and then evaporated in vacuo to yield a solid, which was recrystallized from ethyl acetate [220 mg., 21% yield, m.p. 88°-90° C., elemental analysis calculated: 74.14% C; 11.87% H; 2.01% N; found: 74.35% C; 11.54% H; 2.15% N].
EXAMPLES 15-26
In like manner to that described in Example 14 the following compounds were prepared by using the appropriate 1,3- or 1,2-di-O-(n-higher alkyl or alkenyl)-glycerol and cyanobenzyl bromide as starting materials: ##STR19##
__________________________________________________________________________ Substi- tution Elemental Analysis on CalculatedEx. Struc- Phenyl Molecular (%) Found (%)No. ture R.sub.1 R.sub.2 Ring Formula M.P. (°C.) C H N C H N__________________________________________________________________________15 I n-hexadecyl n-hexadecyl ortho C.sub.43 H.sub.81 O.sub.3 N . HCl 71-73 74.14 11.87 2.01 73.89 11.43 1.9916 I n-hexadecyl n-hexadecyl meta C.sub.43 H.sub.81 O.sub.3 N . HCl 77-79 73.20 11.85 1.98 73.17 11.53 2.2817 I n-hexadecyl n-hexadecyl para C.sub.43 H.sub.81 O.sub.3 N . HCl . H.sub.2 77-78 72.28 11.83 1.96 72.52 11.46 1.9018 II n-tetradecyl n-tetradecyl ortho C.sub.39 H.sub.73 O.sub.3 N . HCl . 1/4 H.sub.2 O 71-72 72.63 11.48 2.17 72.62 11.81 2.4319 II n-hexadecyl n-hexadecyl ortho C.sub.43 H.sub.81 O.sub.3 N . HCl 79-80 74.14 11.87 2.01 73.94 11.25 2.0220 II n-tetradecyl n-tetradecyl meta C.sub. 39 H.sub.73 O.sub.3 N . 87-88 73.14 11.65 2.19 72.86 11.44 2.1121 II n-octadecyl n-octadecyl meta C.sub.47 H.sub.89 O.sub.3 N . HCl 73-75 74.99 12.06 1.86 74.97 11.73 1.8322 II n-octadec-9- n-octadec-9- meta C.sub.47 H.sub.85 O.sub.3 N . HCl . 1/2 H.sub.2 O oil 74.50 11.57 1.85 74.40 11.08 2.08 enyl enyl23 II n-tetradecyl n-tetradecyl para C.sub.39 H.sub.73 O.sub.3 N . HCl 132-135 73.14 11.65 2.19 72.84 11.30 2.2624 II n-hexadecyl n-hexadecyl para C.sub.43 H.sub.81 O.sub.3 N . HCl 117-119 74.14 11.87 2.01 74.33 11.55 2.1525 II n-octadecyl n-octadecyl para C.sub.47 H.sub.89 O.sub.3 N . HCl 67-69 74.99 12.06 1.86 74.50 11.30 1.9126 II n-octadec-9- n-octadec-9- para C.sub.47 H.sub.85 O.sub.3 N . HCl . 3/4 H.sub.2 O oil 74.06 11.54 1.83 74.00 10.99 1.93 enyl enyl__________________________________________________________________________
EXAMPLE 27
1,2-Di-O-(n-hexadecyl)-3-O-(4-aminomethylphenyl)-glycerol Hydrochloride
A. 1,2-Di-O-(n-hexadecyl)-3-O-(p-tosyl)-glycerol
In like manner to that described in Example 13B the named compound was prepared by reacting 1,2-di-O-(n-hexadecyl)-glycerol with p-toluenesulfonyl chloride. Purification was accomplished by recrystallization from ethyl acetate [m.p. 53°-55° C., ir (CHCl 3 ) 1360 and 1180 cm -1 ].
B. 1,2-Di-O-(n-hexadecyl)-3-O-(4-cyanophenyl)-glycerol
A mixture of 1,2-di-O-(n-hexadecyl)-3-O-(p-tosyl)-glycerol (1.4 g., 2.0 mmoles), sodium 4-cyanophenolate (0.5 g., 3.5 mmoles) and xylene (100 ml.) was stirred for 16 hours at reflux. Since the reaction was not yet complete the xylene was removed by distillation and replaced by N,N-dimethylformamide (100 ml.), and the resulting solution stirred for another 16 hours at 150° C. The reaction solution was then cooled, diluted with water (100 ml. and extracted with ether (2×100 ml.). The combined ether extract was washed consecutively with 3 N hydrochloric acid (100 ml.), 10 wt. % aqueous sodium bicarbonate solution (100 ml.) and water (100 ml.), dried (MgSO 4 ), filtered and evaporated in vacuo to an oil, which was purified by silica gel chromatography (elution with benzene) [0.65 g., 50% yield, m.p. 53°-55° C., ir (CHCl 3 ) 2210 cm -1 ].
C. Title Compound
1,2-Di-O-(n-hexadecyl)-3-O-(4-cyanophenol)-glycerol (0.60 g., 0.93 mmole) was added to a suspension of lithium aluminum hydride (0.3 g., 7.9 mmoles) in ether (25 ml.), and the resulting mixture stirred for 30 minutes at room temperature. Water (25 ml.) was then added cautiously, the ether and aqueous phases separated, and the latter extracted with ether (3×25 ml.) and ethyl acetate (25 ml.). The five organic extracts were combined, dried (MgSO 4 ), filtered and evaporated in vacuo to an oil, which was dissolved in ether. The solution was treated with hydrogen chloride gas, causing precipitation of a solid [0.41 g., 64% yield, m.p. 110°-112° C., n.m.r. (CDCl 3 ) δ 4.02 (s, 2, --CH 2 NH 2 ), elemental analysis calculated: 73.91% C; 11.81% H; 2.05% N; found: 73.62% C; 11.71% H; 2.14% N].
EXAMPLES 28-30
In like manner to that described in Example 27 B-C the following compounds were prepared from the appropriate tosylate (prepared as in Example 27A) and sodium cyanophenolate:
__________________________________________________________________________ ##STR20## I ##STR21## II Substitution Elemental AnalysisExample on Molecular Calculated (%) Found (%)NumberStructure Phenyl Ring Formula M.P. (°C.) C H N C H N__________________________________________________________________________28 I meta C.sub.42 H.sub.79 O.sub.3 N . HCl 78-80 73.91 11.81 2.05 74.11 11.64 2.4429 I para C.sub.42 H.sub.79 O.sub.3 N . HCl 120-122 73.91 11.81 2.05 73.94 11.37 2.0430 II meta C.sub.42 H.sub.79 O.sub.3 N . HCl 84-86 73.91 11.81 2.05 74.00 11.34 2.04__________________________________________________________________________
EXAMPLE 31
1,2-Di-O-(n-hexadecyl)-3-O-[4-(3-aminopropyl)phenyl]-glycerol Hydrochloride
In like manner to that described in Example 27 the named compound was prepared by using sodium 4-(2-cyanoethyl)phenolate in place of sodium 4-phenolate (m.p. 153°-155° C., elemental analysis calculated: 74.37% C; 11.91% H; 1.97% N; found: 74.13% C; 11.44% H; 2.08% N).
EXAMPLE 32
1,2-Di(n-hexadecyloxy)-3-(3-aminomethylbenzylamino)-propane Dihydrochloride
1,2-Di-O-(n-hexadecyl)-3-O-(p-tosyl)-glycerol (3.48 g., 5.0 mmoles) was added to a solution of m-xylylenediamine (0.68 g., 5.0 mmoles) in N,N-dimethylformamide (20 ml.). The resulting mixture was stirred for one hour at 90° C. and then poured into ice water (150 ml.), causing the formation of solids which were isolated by filtration, purified by silica gel chromatography (elution with benzene:ethanol) and then dissolved in ethyl acetate. The solution was treated with hydrogen chloride gas and then evaporated in vacuo to yield a solid, which was recrystallized from ethyl acetate [0.29 g., 8% yield, m.p. 78°-80° C., n.m.r. (CDCl 3 ) δ 4.24 (s, 2, Ar--CH 2 NH--) and 4.37 (s, 2, Ar--CH 2 NH 2 ), elemental analysis calculated: 70.55% C; 11.57% H; 3.83% N; found: 70.64% C; 11.29% H; 3.62% N].
EXAMPLE 33
1,2-Di-O-(n-hexadecyl)-3-O-(3-isopropylamino-2-hydroxypropyl)-glycerol Hydrochloride
A. 1,2-Di-O-(n-hexadecyl)-3-O-(2,3-epoxypropyl)-glycerol
A solution of 1,2-di-O-(n-hexadecyl)-3-allyl-glycerol (5.8 g., 10.0 mmoles) and m-chloroperbenzoic acid (1.86 g., 10.8 mmoles) in benzene (50 ml.) was stirred at reflux for 16 hours. The reaction mixture was then cooled, treated with saturated aqueous sodium bisulfite solution (10 ml.) and saturated aqueous sodium bicarbonate solution (50 ml.), and extracted with ether (3×50 ml.). The combined ether extract was washed with water (100 ml.), washed with saturated aqueous sodium chloride solution (100 ml.), dried (MgSO 4 ), filtered and evaporated in vacuo to an oil (4.9 g., 82% yield, olefinic protons absent by n.m.r. analysis), which was purified by silica gel chromatography (elution with benzene:ethyl acetate) (4.2 g., 70% yield, oil-solidified on standing).
B. Title Compound
A solution of 1,2-di-O-(n-hexadecyl)-3-O-(2,3-epoxypropyl)-glycerol (2.0 g., 3.35 mmoles) in isopropylamine (40 ml.) was heated in a stainless steel bomb for 16 hours at 100° C., cooled, concentrated in vacuo and dissolved in ether (100 ml.). The ether solution was washed with 1 N hydrochloric acid (100 ml.), dried (MgSO 4 ), filtered, treated with charcoal, filtered again, and then cooled by immersion of the flask in a Dry Ice-acetone bath, causing formation of a precipitate. The precipitate was isolated by filtration (1.3 g.) and purified by silica gel chromatography (elution with benzene:ethanol) [720 mg., solid contained about 1/2 mole H 2 O per mole named product, 31% yield, m.p. 55°-57° C., n.m.r. (CDCl 3 ) δ 1.45 (d, 6, --NHCH[CH 3 ] 2 ), elemental analysis calculated: 70.19% C; 12.50% H; 2.00% N; found: 70.10% C; 12.19% H; 1.87% N].
EXAMPLES 34-37
In like manner to that described in Example 33B the following compounds were prepared by reacting the appropriate 2,3-epoxide (prepared as in Example 33A) and alkylamine: ##STR22##
__________________________________________________________________________ Elemental AnalysisExample Molecular Calculated (%) Found (%)NumberStructure R.sub.3 Formula M.P.(° C.) C H N C H N__________________________________________________________________________34 I --CH.sub.2 CH.sub.3 C.sub.40 H.sub.83 O.sub.4 N . HCl 53-54 68.97 12.44 2.01 69.35 12.08 1.9435 I --CH(CH.sub.3).sub.2 C.sub.41 H.sub.85 O.sub.4 N . HCl 67-68 71.10 12.52 2.02 70.54 12.18 2.0536 I --C(CH.sub.3).sub.3 C.sub.42 H.sub.87 O.sub.4 N . HCl 60-61 71.39 12.55 1.98 71.55 12.35 1.7937 II --C(CH.sub.3).sub.3 C.sub.42 H.sub.87 O.sub.4 N . HCl . 1/2H.sub.2 O 50-51 70.49 12.53 1.96 70.66 12.31 1.83__________________________________________________________________________
EXAMPLE 38
1,2-Di-O-(n-hexadecyl)-3-O-(3-amino-2-hydroxypropyl)-glycerol Hydrochloride
A. 1,2-Di-O-(n-hexadecyl)-3-O-(3-azido-2-hydroxypropyl)-glycerol
A solution of sodium azide (0.5 g., 7.7 mmoles) in water (5 ml.) was added to a refluxing solution of 1,2-di-O-(n-hexadecyl)-3-O-(2,3-epoxypropyl)-glycerol (3.3 g., 5.5 mmoles) in 1,4-dioxane (100 ml.), and the resulting solution stirred at reflux for 16 hours. Since the reaction was not yet complete, additional sodium azide (0.5 g., 7.7 mmoles) was added and the reaction stirred at reflux for another 16 hours. The reaction solution was then cooled, concentrated in vacuo, diluted with water (100 ml.) and extracted with ether (3×100 ml.). The combined ether extract was washed with water (100 ml.), dried (MgSO 4 ), filtered and evaporated in vacuo to an oil which solidified on standing [2.2 g., 62% yield, ir (CHCl 3 ) 2105 cm -1 ].
B. Title Compound
Lithium aluminum hydride (300 mg., 7.9 mmoles) was added to a solution of 1,2-di-O-(n-hexadecyl)-3-O-(3-azido-2-hydroxypropyl)-glycerol (2.2 g., 3.4 mmoles) in ether (100 ml.), and the resulting mixture stirred for one hour at room temperature. Ethanol (5 ml.) and water (200 ml.) were added to quench the reaction, and the mixture then extracted with ether (2×100 ml.). The combined ether extract was dried (MgSO 4 ), filtered and evaporated in vacuo. The resulting product was purified by silica gel chromatography (elution with benzene:ethanol) and then converted to the hydrochloride salt [800 mg., solid contained about 2 moles H 2 O per mole named product, 34% yield, m.p. 149°-150° n.m.r. (CDCl 3 ) δ 4.00-4.35 (m, 1, --OCH 2 CHOCHCH 2 NH 2 ), 3.33-3.73 (m, 11, C 15 H 31 CH 2 OCH 2 CH[OCH 2 C 15 H 31 ]CH 2 OCH 2 --), 3.03-3.25 (m, 2, --OCH 2 CHOHCH 2 NH 2 ) and 0.87-1.67 (m, 62, aliphatic protons), elemental analysis calculated: 66.48% C; 12.33% H; 2.04% N; found: 66.68% C; 11.85% H; 2.02% N].
EXAMPLE 39
1,3-Di-O-(n-hexadecyl)-2-O-(3-amino-2-hydroxypropyl)-glycerol
In like manner to that described in Example 38 the named compound was prepared from 1,3-di-O-(n-hexadecyl)-2-O-(2,3-epoxypropyl)-glycerol (prepared as in Example 33A) (free base, m.p. 61°-63° C., elemental analysis calculated: 74.33% C; 12.96% H; 2.28% N; found: 74.49% C; 13.10% H; 2.12% N).
EXAMPLE 40
1,2-Di-O-(n-hexadecyl)-3-O-(2-aminopropyl)-glycerol Hydrochloride
A. 1,2-Di-O-(n-hexadecyl)-3-O-[2-(p-tosyloxy)propyl]-glycerol
In like manner to that described in Example 13A and B, 1,2-di-O-(n-hexadecyl)-3-O-allyl-glycerol was reacted with BMS, and the resulting 2-hydroxypropyl and 3-hydroxypropyl compounds converted to their corresponding tosylates. A separation was not attempted at this stage; the mixture of tosylates was used directly in the next step.
B. 1,2-Di-O-(n-hexadecyl)-3-O-(2-azidopropyl)-glycerol
The resulting mixture of tosylates (3.0 g., 4.0 mmoles) was dissolved in N,N-dimethylacetamide (50 ml.) and treated with a solution of sodium azide (0.326 g., 5.0 mmoles) in water (5 ml.) for 16 hours at 90° C. The reaction solution was then cooled, diluted with water (200 ml.), and extracted with ether (2×150 ml.). The combined ether extract was washed with water, dried (MgSO 4 ), filtered, and evaporated in vacuo to an oil [2 g., 81% yield, ir (CHCl 3 ) 2100 cm -1 ], a mixture of the 2-azidopropyl and 3-azidopropyl compounds, which was used without further purification in the next step.
C. Title Compound
The resulting mixture of azides (2 g., 3.2 mmoles) was dissolved in ether (100 ml.), treated with lithium aluminum hydride (0.4 g., 10.5 mmoles), and allowed to stir for 2 hours at room temperature. Excess hydride was destroyed by cautious addition of ethanol (10 ml.) and water (150 ml.), and the mixture then extracted with ether (2×100 ml.). The combined ether extract was dried (MgSO 4 ), filtered, and concentrated in vacuo to an oil (1.8 g.), which was purified by silica gel chromatography (elution with benzene:ethanol) and then converted to the hydrochloride salt by dissolution and treatment with hydrogen chloride gas. The salt was recrystallized from ethyl acetate (0.21 g., solid contained about 1/2 mole H 2 O per mole named product, 10% yield, m.p. 56°-58° C. elemental analysis calculated: 71.03% C; 12.70% H; 2.18% N; found: 71.11% C; 12.91% H; 2.16% N).
EXAMPLE 41
1,2-Di-O-(n-octadecyl)-3-O-(2-aminopropyl)-glycerol Hydrochloride
In like manner to that described in Example 40A, 1,2-di-O-(n-octadecyl)-3-O-(2-hydroxypropyl)-glycerol was prepared from 1,2-di-O-(n-octadecyl)-3-O-allyl-glycerol. The named compound was prepared from 1,2-di-O-(n-octadecyl)-3-O-(2-hydroxypropyl)-glycerol in like manner to that described in Example 40 B-C (solid contained about 1 mole H 2 O per mole named product, m.p. 65°-67° C., elemental analysis calculated: 71.19% C; 12.80% H; 1.98% N; found: 71.12% C; 12.52% H; 1.92% N).
EXAMPLE 42
1,2-Di(n-hexadecyloxy)-3-aminopropane Hydrochloride
In like manner to that described in Example 40B, 1,2-di-O-(n-hexadecyl)-3-O-(p-tosyl)-glycerol was converted to 1,2-di-(n-hexadecyloxy)-3-azidopropane. This intermediate was converted to the title compound in like manner to that described in Example 40C (m.p. 78°-80° C., elemental analysis calculated: 72.93% C; 12.94% H; 2.43% N; found: 73.08% C; 13.08% H; 2.65% N).
EXAMPLE 43
1,3-Di(n-hexadecyloxy)-2-aminopropane Hydrochloride
In like manner to that described in Example 42 the named compound was prepared from 1,3-di-O-(n-hexadecyl)-2-O-(p-tosyl)-glycerol (prepared as in Example 27A) (m.p. 58°-60° C., elemental analysis calculated: 72.93% C; 12.94% H; 2.43% N; found: 72.65% C; 13.02% H; 2.59% N).
EXAMPLE 44
1,2-Di(n-hexadecyloxy)-4-aminobutane Hydrochloride
In like manner to that described in Example 42 the named compound was prepared by using sodium cyanide in place of sodium azide (m.p. 86°-87° C., elemental analysis calculated: 73.25% C; 12.97% H; 2.37% N; found: 73.52% C; 12.64% H; 2.50% N).
EXAMPLE 45
1,3-Di(n-hexadecyloxy)-2-(3-aminopropylamino)propane Dihydrochloride
A. 1,3-Di(n-hexadecyloxy)-2-(2-cyanoethylamino)propane
A mixture of 1,3-di(n-hexadecyloxy)-2-aminopropane (500 mg., 0.93 mmoles), acrylonitrile (75 ml.) and 2 wt. % aqueous sodium hydroxide solution (75 ml.) was heated to 60° C. Tetrabutyl ammonium hydroxide (1 ml. of 40 wt. % aqueous solution) was then added and the resulting mixture stirred for 15 minutes at 90° C. The reaction mixture was then cooled, causing precipitation of solids, which were isolated by filtration and found (TLC) to contain a large quantity of unreacted starting material. Using fresh acrylonitrile and aqueous sodium hydroxide solution in each cycle, the solids were treated two more times by the above procedure. The third cycle solid product was purified by silica gel chromatography (elution with toluene:ethyl acetate) [200 mg., 36% yield, m.p. 45°-46° C., ir (CHCl 3 ) 2250 cm -1 , n.m.r. (CDCl 3 ) δ 3.07 (t, 2, --NHCH 2 CH 2 CN) and 2.53 (t, 2, --NHCH 2 CH 2 CN)].
B. Title Compound
A mixture of 1,3-di(n-hexadecyloxy)-2-(2-cyanoethylamino)-propane (200 mg., 0.34 mmoles), tetrahydrofuran (10 ml.), ethanol (20 ml.) and Raney nickel catalyst (0.2 g.) was saturated with ammonia gas and then hydrogenated (50 psi) for about 4 hours at room temperature. The reaction mixture was then filtered and evaporated in vacuo to an oil, which was purified by silica gel chromatography (elution with toluene:ethyl acetate:ethanol:methanol) and then dissolved in ethyl acetate. The solution was treated with hydrogen chloride gas, causing precipitation of solids [10 mg., solid contained about 2.5 moles H 2 O per mole named product, 4% yield, m.p. 235°-236° C., elemental analysis calculated: 63.65% C; 12.51% H; 3.90% N; found: 63.60% C; 11.84% H; 3.75% N].
EXAMPLE 46
1,2-Di-O-(n-hexadecyl)-3-O-(4-amidinophenyl)-glycerol Hydrochloride
A solution of 1,2-di-O-(n-hexadecyl)-3-O-(4-cyanophenyl)-glycerol (3.5 g., 5.45 mmoles), ethanol (10 ml.) and 1,4-dioxane (100 ml.) was saturated with hydrogen chloride gas at 0° C., and allowed to react for 16 hours at ambient temperature. The reaction solution was then evaporated in vacuo to an oil, the oil dissolved in ethanol (100 ml.), and the resulting solution saturated with ammonia gas, stirred for 3 hours at reflux, diluted with water (150 ml.), evaporated in vacuo to remove the majority of the ethanol, and extracted with chloroform (3×150 ml.). The combined chloroform extract was dried (MgSO 4 ), filtered and evaporated in vacuo to yield a solid, which was purified by silica gel chromatography (elution with benzene:ethanol) and then dissolved in ethyl acetate. The solution was treated with hydrogen chloride gas and then evaporated in vacuo to yield a solid, which was recrystallized from ethyl acetate [1.0 g., 26% yield, m.p. 220°-222° C., ir (CHCl 3 ) 1670 cm -1 , elemental analysis calculated: 72.53% C; 11.45% H; 4.03% N; found: 72.67% C; 11.38% H; 4.12% N].
EXAMPLE 47
1,2-Di-O-(n-hexadecyl)-3-O-(3-amidinobenzyl)-glycerol Hydrochloride
The named compound was prepared from 1,2-di-O-(n-hexadecyl)-3-O-(3-cyanobenzyl)-glycerol in like manner to that described in Example 46 [solid contained about 2 moles H 2 O per mole named product, 20% yield, m.p. 155°-157° C., ir (CHCl 3 ) 1670 cm -1 , elemental analysis calculated: 69.27% C; 11.48% H; 3.76% N; found: 69.11% C; 10.63% H; 3.83% N].
EXAMPLE 48
1,2-Di-O-(n-hexadecyl)-3-O-[3-(1-hydroxy-2-t-butylaminoethyl)-benzyl]-glycerol Hydrochloride
A. 1,2-Di-O-(n-hexadecyl)-3-O-(3-formylbenzyl)-glycerol
A solution of 1,2-di-O-(n-hexadecyl)-3-O-(3-cyanobenzyl)-glycerol (5.0 g., 7.6 mmoles) and diisobutylaluminum hydride (1.17 g., 8.2 mmoles) in benzene (25 ml.) was stirred for 16 hours at ambient temperature. The reaction mixture was treated with methanol (4.22 ml.) and water (2.5 ml.) and stirred to decompose unreacted hydride, and then filtered and extracted with benzene (3×25 ml.). The combined benzene extract was dried (Na 2 SO 4 ), filtered and evaporated in vacuo to an oil, which was purified by silica gel chromatography (elution with benzene) [2.0 g., 40% yield, oil, ir (CHCl 3 ) 1700 cm -1 , n.m.r. (CDCl 3 ) δ 10.1 (s, 1, --ArCHO)].
B. 1,2-Di-O-(n-hexadecyl)-3-O-[3-(1,2-epoxyethyl)-benzyl]-glycerol
A suspension of sodium hydride (3.23 g. of a 57 wt. % dispersion in mineral oil, 67 mmoles) in dimethylsulfoxide (117 ml.) was heated under a nitrogen atmosphere at 70° to 75° C. until hydrogen evolution stopped (45 min.). Tetrahydrofuran (88 ml.) was added and the mixture cooled to 0° to 5° C. Trimethylsulfonium iodide (13.67 g., 67 mmoles) was then added in portions, followed by rapid addition of a solution of 1,2-di-O-(n-hexadecyl)-3-O-(3-formylbenzyl)-glycerol (7.0 g., 10.6 mmoles) in tetrahydrofuran (58 ml.). The resulting mixture was stirred for 16 hours at room temperature, poured into water (200 ml.) and extracted with ether (3×180 ml.). The combined ether extract was washed with water (2×100 ml.) and saturated aqueous sodium chloride solution (100 ml.), dried (MgSO 4 ), filtered and evaporated in vacuo to an oil (7.0 g., 98% yield), which was sufficiently pure to be used in the next step.
C. Title Compound
A mixture of t-butylamine (30 ml.) and 1,2-di-O-(n-hexadecyl)-3-O-[3-(1,2-epoxyethyl)-benzyl]-glycerol (2.0 g., 3.0 mmoles) was heated for 9 hours at 100° C. in a steel bomb. The reaction mixture was cooled, t-butylamine removed by evaporation in vacuo, and the resulting oil purified by silica gel chromatography (elution with benzene:ethanol) and then dissolved. The solution was saturated with hydrogen chloride gas and then evaporated in vacuo to yield a solid, which was recrystallized from ethyl acetate [630 mg., solid contained about 1 mole H 2 O per mole named product, 27% yield, m.p. 49°-51° C., n.m.r. (CDCl 3 ) δ 1.47 (s, 9, --C[CH 3 ] 3 ), elemental analysis calculated: 71.99% C; 11.83% H; 1.75% N; found: 71.86% C; 11.30% H; 1.69% N].
EXAMPLE 49
1,3-Di-O-(n-hexadecyl)-2-O-[3-(1hydroxy-2-t-butylaminoethyl)-benzyl]-glycerol Hydrochloride
In like manner to that described in Example 48 A-B, 1,3-di-O-(n-hexadecyl)-2-O-(3-cyanobenzyl)-glycerol (prepared as in Example 14A) was converted to 1,3-di-O-(n-hexadecyl)-2-O-[3-(1,2-epoxyethyl)-benzyl]-glycerol. The title compound was prepared by reacting said epoxy compound with t-butylamine in like manner to that described in Example 48C (solid contained about 1 mole H 2 O per mole named product, m.p. 43°-45° C., elemental analysis calculated: 71.99% C; 11.83% H; 1.75% N; found: 72.06% C; 11.43% H; 1.71% N).
EXAMPLE 50
1,2-Di-O-(n-hexadecyl)-3-O-[3-(1-hydroxy-2-isopropylaminoethyl)-benzyl]-glycerol Hydrochloride
In like manner to that described in Example 48C the named compound was prepared by using isopropylamine in place of t-butylamine (solid contained about 3/4 mole H 2 O per mole named product, m.p. 53°-55° C., elemental analysis calculated: 72.17% C; 11.79% H; 1.79% N; found: 72.11% C; 11.55% H; 1.92% N).
EXAMPLE 51
1-[2,3-Di(n-hexadecyloxy)propyl]-4-aminomethyl-4-phenylpiperidine Dihydrochloride
A. 1-[2,3-Di(n-hexadecyloxy)propyl]-4-cyano-4-phenylpiperidine
A mixture of 1,2-di-O-(n-hexadecyl)-3-O-(p-tosyl)-glycerol (6.96 g., 10 mmoles), 4-cyano-4-phenylpiperidine hydrochloride (2.23 g., 10 mmoles), triethylamine (2 ml.) and N,N-dimethylformamide (40 ml.) was stirred for 16 hours at 95° to 100° C. The reaction mixture was then cooled, diluted with water (200 ml.) and extracted with ethyl acetate (3×150 ml.). The combined ethyl acetate extract was dried (MgSO 4 ), filtered and evaporated in vacuo to an oil (6 g.), which was purified by column chromatography (elution with benzene:ethyl acetate) [oil, ir (CHCl 3 ) 2220 cm -1 ].
B. Title Compound
A solution of 1-[2,3-di(n-hexadecyloxy)propyl]-4-cyano-4-phenylpiperidine (2.5 g., 3.6 mmoles) in ether (100 ml.) was treated with lithium aluminum hydride (0.4 g., 10.5 mmoles), and the resulting mixture stirred for 4 hours at room temperature. The reaction mixture was treated cautiously with water (100 ml.) and extracted with ether (3×100 ml.). The combined ether extract was dried (MgSO 4 ), filtered and evaporated in vacuo to an oil, which was purified by silica gel chromatography (elution with benzene:ethanol) and then dissolved. The solution was treated with hydrogen chloride gas and then evaporated in vacuo to yield a solid, which was recrystallized from ethyl acetate (1.1 g., solid contained about 3/4 mole H 2 O per mole named product, 40% yield, m.p. 132°-134° C., elemental analysis calculated: 70.60% C; 11.53% H; 3.50% N; found: 70.74% C; 11.34% H; 3.40% N).
EXAMPLES 52-54
In like manner to that described in Example 51 the following compounds were prepared from the appropriate 1,2-di-O-(n-alkyl or alkenyl)-3-O-(p-tosyl)-glycerol (prepared as in Example 27A): ##STR23##
__________________________________________________________________________ Elemental AnalysisExample Molecular Calculated (%) Found (%)NumberR Formula M.P.(° C.) C H N C H N__________________________________________________________________________52 n-tetradecyl C.sub.43 H.sub.80 O.sub.2 N.sub.2. 2HCl 140-142 69.46 11.25 3.75 69.45 11.00 3.4553 n-octadecyl C.sub.51 H.sub.96 O.sub.2 N.sub.2 . 2HCl 115-117 71.95 11.60 3.29 71.67 11.19 3.3854 n-octadec-9-enyl C.sub.51 H.sub.92 O.sub.2 N.sub.2 . 2HCl 118-120 71.17 11.23 3.25 71.06 10.84 3.09__________________________________________________________________________
EXAMPLE 56
1,2-Di-O-(n-hexadecyl)-3-O-(2-[di(2-hydroxyethyl)amino]ethyl)-glycerol Hydrochloride
In like manner to that described in Example 11 the named compound was prepared by reacting 1,2-di-O-(n-hexadecyl)-3-O-formylmethyl-glycerol with di(2-hydroxyethyl)amine (solid contained about 1/4 mole H 2 O per mole named product, m.p. 194°-195° C., elemental analysis calculated: 69.06% C; 12.20% H; 1.96% N; found: 69.12% C; 11.76% H; 1.90% N).
EXAMPLE 57
In Vivo Activity of 1,3-Di-O-(n-hexadecyl)-2-O-(3-aminopropyl)-glycerol Hydrochloride Against EMC Virus
Formulation as an emulsion was accomplished by melting and mixing equal parts of the named compound, polysorbate 80, and glycerin, and then dispersing the mixture in hot water under vigorous mixing. The formulation was then adjusted to final concentrations of 0.14 M sodium chloride and 0.01 M sodium phosphate, pH 7. Further dilutions were made with 0.14 M sodium chloride--0.01 M sodium phosphate, pH 7 buffer solution.
Three groups of ten female albino mice (20-25 g. body weight) were given 0.5 ml. intraperitoneal injections containing dosage levels of 1.5, 5 and 15 mg. of the named compound/kg. body weight, respectively. A fourth control group of ten mice was given no such injection. Eighteen to twenty-four hours later all four groups were challenged with 0.2 ml. subcutaneous injection containing 20 times the LD 50 , the dosage level causing a 50% death rate in unprotected mice in ten days, of encephalomyocarditis (EMC) virus. Survival data were recorded over the next ten days and the relative survival (S r ) calculated:
______________________________________Dosage Level OfNamed Compound S.sub.r (average of seven experiments)______________________________________15 mg./kg. 61 5 451.5 24______________________________________
Antiviral activity is expressed as the relative survival (S r ) in experimental groups compared to the control on the tenth day after challenge. S r is defined by the formula ##EQU1## wherein S r =relative survival
S x =percent survival after ten days in experimental group
x i =number of survivors on the ith day in experimental group
e i =number of survivors on the ith day in control group
EXAMPLES 58-86
In like manner to that described in Example 57 the in vivo activity against EMC virus was determined for the compounds listed below.
______________________________________ CompoundExample Prepared in S.sub.r at Dosage Level (mg./kg.) ofNumber Example Number 15 5 1.5 0.5______________________________________58 14 71 49 20 659 15 62 47 18 --60 16 80 72 20 --61 17 74 46 4 --62 18 57 42 3 --63 19 64 58 15 --64 20 74 44 34 --65 21 46 7 6 --66 22 45 5 4 --67 23 70 36 3 --68 24 37 31 12 069 25 44 30 8 --70 26 68 43 2 --71 27 66 45 17 --72 28 68 28 33 --73 29 60 63 16 --74 30 53 34 16 775 31 56 35 20 676 32 63 41 31 --77 42 33 26 26 --78 43 30 30 7 --79 44 51 20 7 --80 46 32 3 0 --81 47 56 16 6 --82 51 77 58 26 --83 52 76 85 42 --84 53 52 42 32 --85 54 79 72 28 --86 49 99 26 54 --______________________________________
EXAMPLE 87
Reduction of Virus Yield on Human Polyp Cells In Vitro by 1,3-Di-O-(n-hexadecyl)-2-O-(3-aminopropyl)-glycerol Hydrochloride
Growth medium was prepared by supplementing Eagle's minimum essential medium (100 ml.) with 100× concentrated antibiotic-antimycotic solution (2 ml.), 200 mM glutamine solution (1 ml.), 100× concentrated nonessential amino acids solution (1 ml.), 100 mM sodium pyruvate solution (1 ml.), and heat-inactivated fetal calf serum (10%). Each well of 96-well microtiter plates was seeded with about 50,000 human nasal polyp cells suspended in 0.2 ml. growth medium. The plates were then incubated for 8-10 days at 37° C. in a 5% CO 2 atmosphere to establish monolayers of cells.
At the end of the 8-10 day cell growth period confluent monolayers on the plates were washed four times with phosphate buffered saline and immediately afterward treated with 0.2 ml. per well of maintenance medium containing 10, 5.0, 1.0, 0.5, 0.1 and 0 μg./ml. of the named compound, respectively. The maintenance medium was identical to the growth medium described above except that the level of said fetal calf serum was 2%. The plates were incubated for another 18 hours at 37° C., and the monolayers then washed four times with phosphate buffered saline to remove the named compound, challenged with a composition containing about 1000 times the TCID 50 , i.e. the dosage level causing a 50% infection rate in unprotected cultures, of vesicular stomatitis virus (VSV) for a two hour (37° C.) adsorption period, washed four times with phosphate buffered saline to remove unadsorbed virus particles, and refed with 0.2 ml. per well of said maintenance medium. The plates were then incubated for 7 hours at 37° C., and the culture fluid from 5-8 replicate cells harvested from each plate, stored frozen in test tubes, and then titrated for the amount of infectious virus present in microtiter plates of L-929 mouse fibroblasts. The L-929 mouse cultures were scored microscopically and analyzed about three to four days later, with the following percentage decreases in virus yield (with respect to the control) determined for the five concentrations of named compound tested:
______________________________________Percentage Reduction of Virus YieldConcentration (μg./ml.) of Named Compound10 5.0 1.0 0.5 0.1______________________________________94% 90% 84% 75% <68%______________________________________
EXAMPLES 88-121
In like manner to that described in Example 87 the reduction of virus yield on human polyp cells in vitro was determined for the compounds listed below.
______________________________________ Compound Percentage Reduction of VirusExample Prepared in Yield.sup.a Concentration (μg./ml.)Number Example Number 10 5.0 1.0 0.5 0.1______________________________________88 6 + + - - ND89 9 ND ± - - ND90 11 + + - ND ND91 12 + + - ND ND92 13 + ± - ND ND93 14 + + - - -94 18 + - - ND ND95 19 + + - - -96 20 + ± - - -97 22 + ± - - -98 23 + ± - - -99 28 + + - - -100 30 + + - ND ND101 31 + + - ND ND102 33 + + - ND ND103 34 ND + - ND ND104 35 + ± - ND ND105 36 + - - ND ND106 37 + + - ND ND107 38 + + - - ND108 40 + + - ND ND109 41 ND + - ND ND110 42 + + - - ND111 44 + + - ND ND112 45 + - - ND ND113 47 + + - - -114 56 + - - ND ND115 48 + + - - ND116 49 - - - - ND117 50 + + - - ND118 51 + ± - - ND119 52 + + - - ND120 53 + + - - ND121 54 + - - - ND______________________________________ .sup.a + ≡ >68% reduction; ± ≡ ˜68% reduction; - ≡ <68% reduction; ND ≡ not done.
EXAMPLE 122
Ability of 1,3-Di-O-(n-hexadecyl)-2-O-(3-aminopropyl)-glycerol Hydrochloride to Induce Circulating Interferon
A mixture of equal weights of the named compound, polysorbate 80 and glycerol was fused and then homogenized in hot 0.14 M sodium chloride containing 0.01 M sodium phosphate, pH 7 (PBS). The resulting oil-in-water emulsion was readily diluted with PBS for administration.
Female Swiss mice (20-25 g. body weight) were injected (0.5 ml., intraperitoneal) with a quantity of the above diluted emulsion containing 25 mg. of the named compound/kg. body weight. Eight, twelve, sixteen and twenty hours after injection samples of plasma were withdrawn from four mice and pooled. Serial dilutions in L-15 (Leibovitz) medium containing 5% fetal calf serum were incubated in microtiter plates overnight at 37° C. on confluent monolayers of L-929 mouse fibroblasts. The monolayers were then washed with protein-free medium, challenged with 10 times the TCID 50 , i.e. the dosage level causing a 50% infection rate in unprotected cultures, of vesicular stomatitis virus (VSV) for a one hour (37° C.) absorption period, washed, retreated with L-15 medium containing 5% fetal calf serum and then incubated again for 48 hours at 37° C. The L-929 cultures were then scored microscopically for viral cytopathology and analyzed, with the plasma interferon level, the reciprocal of the plasma dilution conferring 50% protection to the L-929 monolayers, determined.
A second experiment followed the above procedure, except that the mice were injected with 10 mg. of the named compound/kg. body weight and samples of peritoneal wash were taken from four mice and pooled at six, nine, twelve, fifteen and eighteen hours after injection. The samples were taken by exposing the peritoneal membrane, injecting 1 ml. of Hank's balanced salt solution containing 100 penicillin units/ml. and 100 μg. streptomycin/ml. into the peritoneal cavity, briefly massaging the abdomen, and then aspirating the peritoneal wash.
The following data were obtained from these two experiments:
______________________________________ Interferon Levels (units/ml.)Source of Time (hrs.) after InjectionInterferon 6 8 9 12 15 16 18 20______________________________________Plasma -- 34 -- 67 -- 52 -- 40Peritonealwash <16 -- 768 320 448 -- 448 --______________________________________
EXAMPLES 123-129
In like manner to that described in Example 122 the ability to induce circulating interferon was determined for the compounds listed below.
__________________________________________________________________________ Interferon Levels (units/ml.).sup.a Interferon Levels (units/ml.).sup.bExampleCompound Prepared in Time (hrs.) after Injection Time (hrs.) after InjectionNumberExample Number 8 12 16 20 6 9 12 15 18__________________________________________________________________________123 14 <20 23 75 90 <13 <13 39 35 72124 15 20 71 54 68 <18 <18 43 59 32125 16 <18 138 217 163 <13 <13 43 92 57126 24 <20 28 60 70 <13 <-- 91 109 50127 32 38 33 45 35 <13 79 49 52 <13128 47 <17 19 45 99 <16 32 96 640 512129 51 70.sup.c 100 120.sup.d 100.sup.e <13 109 284 312 224__________________________________________________________________________ .sup.a Interferon sourceplasma .sup.b Interferon sourceperitoneal wash .sup.c <20 units/ml. at 6 hrs., 70 units/ml. at 9 hrs. .sup.d 15 hrs. .sup.e 18 hrs.
EXAMPLE 130
Enhancement of Polyinosinic-Polycytidylic Acid [Poly(I:C)]-induced Cellular Resistance to Viral Infection by 1,3-Di-O-(n-hexadecyl)-2-O-(3-aminopropyl)-glycerol Hydrochloride
Growth medium was prepared by supplementing Eagle's minimum essential medium (100 ml.) with 100× concentrated antibiotic-antimycotic solution (2 ml.), 200 mM glutamine solution (1 ml.), an heat-inactivated fetal calf serum (5%). Mouse L-929 fibroblasts were suspended in growth medium, and each well of 96-well microtite plates was seeded with 0.2 ml. of said suspension containing 20,000 to 30,000 cells. The plates were incubated for 2 to 4 days at 37° C. in a 5% CO 2 atmosphere to establish monolayers of cells. The plates were washed four times with phosphate buffered saline immediately prior to treatment.
Poly (I:C) was prepared at concentrations of 5.0, 1.0, 0.2 and 0.04 μg./ml. in the medium described above minus calf serum. 0.1 ml. of each dilution was combined in a checkerboard arrangement on the L-929 cell monolayers with 0.1 ml. dilutions containing 20.0, 4.0, 0.8, 0.16 and 0.032 μg. of the named compound per ml. said serum-free medium. Control wells were exposed to either poly(I:C) or the named compound alone. The plates were incubated for 6 hours at 37° C. in a 5% CO 2 atmosphere, washed four times with phosphate buffered saline, and refed with 0.1 ml. per well growth medium containing 2% fetal calf serum. After 18 more hours of incubation, the plates were scored for toxicity and then challenged with 0.1 ml. per well of a vesicular stomatitis virus (VSV) suspension containing 10 to 30 times the TCID 50 (tissue culture infective dose causing a 50% infection rate). The plates were incubated for another 3 to 4 days and then scored microscopically for cytopathogenic effect (CPE). Cells protected from virus infection were free of CPE. The minimum protective dose (MPD) of poly (I:C) alone was noted, and the amount of enhanced or augmented antiviral activity caused by combination with the named compound recorded for each dilution level of said named compound.
______________________________________Enhancement of Poly (I:C)-inducedCellular Resistance to Viral InfectionConcentration (μg./ml.) of Named Compound20.0 4.0 0.8 0.16 0.032______________________________________125X 125X 125X 5X <5X______________________________________
Note: combining poly(I:C) with named compound provides same antiviral effect as increasing poly (I:C) concentration indicated number of times.
EXAMPLES 131-162
In like manner to that described in Example 130 the enhancement of poly(I:C)-induced cellular resistance to viral infection was determined for the compounds listed below.
______________________________________ Poly(I:C) Enhancement.sup.aExample Compound Prepared in Concentration (μ g./ml.)Number Example Number 20 4.0 0.8______________________________________131 6 + + -132 7 + + -133 14 + + ±134 15 + + ±135 16 + + ±136 17 + + ±137 18 + + ±138 19 + + ±139 20 + + ±140 21 + ± -141 22 - - -142 23 + + ±143 24 + + ±144 25 + + -145 26 + - -146 27 + + -147 28 + + -148 29 + + -149 30 + + ±150 31 + + -151 32 + + ±152 40 + + ±153 41 + + -154 42 + + +155 43 + + +156 44 + + ±157 46 + + ±158 47 + + ±159 51 + + ±160 52 + + -161 53 + + ±162 54 ± - -______________________________________ .sup.a + ≡ >5X enhancement; ± ≡ ˜5X enhancement; - ≡ <5X enhancement; ND ≡ not done. | Novel amine and amidine derivatives of di-O-(n-higher alkyl and alkenyl)-glycerols and -propanediols, and their pharmaceutically acceptable acid addition salts, are useful for combating viral infections in mammals. Of particular interest is 1,3-di-O-(n-hexadecyl)-2-O-(3-aminopropyl)-glycerol, and its pharmaceutically acceptable acid addition salts. | 98,165 |
FIELD OF THE INVENTION
[0001] The present invention relates to containers for containing products that are sensitive to radiation, especially light, essentially of the food industry, more particularly milk and further dairy products, including nutrients and dairy products that are enriched or contain fruit.
[0002] The present invention also relates to a preform, serving as a semi-finished product, for making such containers, consisting of at least one base layer made of is a primary plastic material, with a certain amount of additives incorporated in it.
BACKGROUND OF THE INVENTION
[0003] Plastic containers including bottles made of polyesters and notably polyethylene terephthalate (PET) are increasingly employed for packaging food and drinks. PET containers were originally used for carbonated beverages, such as soda water. They have since gained considerable ground in all areas of the food sector, such as drinks, including milk.
[0004] Polyethylene terephthalate is an excellent material for packaging pasteurized milk, which does not keep for long and is distributed and kept cold, with a shelf life of 7-10 days. However, the absence of a built-in light barrier extending across the whole container greatly hampers the use of all-PET plastic formulations for packaging sterilized, long-life ultra-high temperature (UHT) milk, which keeps for 4-6 months at a normal temperature.
[0005] One of the problems with milk and dairy products generally lies in their unstable nature. The fact is that they can be attacked by undesirable external effects forming part of the prevailing conditions of the surroundings. Their keeping properties therefore depend to a great extent on the way they are packed.
[0006] Owing to the absence of protection from light in the existing packaging units, the milk in them undergoes photo-oxidation. This causes undesirable off-flavours associated with the action of light, Riboflavin (vitamin B 2 ) is also readily attacked, and so are some of the other vitamins and nutrients, which similarly undergo photo-degradation in the presence of light.
[0007] It is well known that milk is degraded by exposure to visible but also invisible light, mainly in the wavelength range between 200 and 550 nm. It must therefore be protected at all cost from harmful light of such wavelengths in order to ensure that the quality of milk is retained for the entire shelf life scheduled for it.
[0008] In the case of products containing additional nutrients that are sensitive to oxygen, the penetration of the latter must also be reduced as much as possible in order to stop the deterioration of the quality. Packs have therefore been developed for UHT milk to prevent the penetration both of visible light and of UV radiation. Multilayer carton packs with a full light barrier have thus been introduced, as well as aluminium foil to prevent the penetration of oxygen. However, the keeping qualities of the contents of these packs after opening leave something to be desired, owing to the closure of these packaging units.
PRIOR ART
[0009] The Japanese document JP 55 117632 A of MITSUBISHI RAYON describes a plastic container with a transparent neck and an opaque body, so that not all its parts have the same opacity, and the light barrier is not present over the whole container, i.e. it does not extend over the neck section. Furthermore, these containers are only intended for cosmetics.
[0010] The European Patent Application EP 0 273 681 A2 of MOBIL OIL CORP describes a process for making polymer films that become glossy when incorporating high percentages of additives up to 30%, to ensure the required opacity in the end product, but they do not have a definite three-dimensional shape and actually do not even have a shape of their own at all. In addition, the additive concentration in them is quite high. It is also stressed here that the additive must have a higher glass transition temperature T g and a higher melting temperature T m than the base polymer used as the primary material, which is a set precondition for being able to keep the mixture in the molten state. This is of course a significant limitation, since the material must inevitably be melted during its processing. Besides, this document does not give any information about the specificity connected with the well-defined three-dimensional shape of the object envisaged here.
[0011] The American patent U.S. Pat. No. 4,410,482 A of SUBRAMANIAN PALLATHERI yet describes extruded and blown bottles made from mixtures of polymers, but again high percentages, up to 40% of additives are used in them, i.e. even more than in the case depicted above.
[0012] The European Patent Application EP 0 974 438 A1 of TEIJIN Ltd yet describes polymer mixtures, but they are intended for transparent containers, whose light-barrier properties appear to be unsatisfactory, or at least call for considerable improvement.
[0013] The European Patent Application EP 0 273 897 A2 of MONSANTO EUROPE S.A. describes aerosol-type pressurized containers made from non-opaque preforms that consist of mixtures of PET and additives of the type of styrene-maleic anhydride (SMA) copolymer, yet with a still high concentration of the latter up to 30%. The purpose of this additive is mainly to make the resulting PET containers more rigid, so that they are able to fairly resist the high pressures used in aerosol-type containers envisaged here. However, this document does not contribute to solve the present problem about the improvement of the walls of the packs for excluding the incident light, which in case of ordinary containers are characterised by a proper shape under normal atmospheric pressure of about 1 atm. Nor does this document describe an opaque preform.
AIM OF THE INVENTION
[0014] The aim of the present invention is to solve the problem mentioned above by including additives that are easier to manage and are more suitable, as regards both their nature and amount, in the primary base material under the abovementioned normal conditions of use, mainly pressure but also to some extent temperature, notably under the atmospheric conditions of the surroundings.
SUMMARY OF THE INVENTION
[0015] There is thus proposed in the present invention a preform, which is remarkable in that it is opaque and consists of a primary plastic material and a low percentage of additives to ensure a whitish opaque appearance over virtually the whole preform. Thanks to the preform proposed according to the invention, an opaque container such as a bottle can be directly obtained that reliably protects its contents from external radiation, especially electromagnetic radiation and more specifically light, whether natural or artificial and whether visible or ultraviolet. It will be understood that we are dealing here with ordinary containers that have stiff or semi-rigid walls of a predetermined shape and which do not have to meet special requirements such as those needed for high pressure. The containers proposed according to the invention are yet intended for use at normal pressure. Opaque preforms are thus proposed which serve as semi-finished intermediate products that can be easily and directly converted into containers that have efficient light barrier properties. In particular, the refractive index of the primary base material is modified here to such an extent that the incident radiation suffers virtually no refraction. As a result, the drink or food kept in the container is protected from harmful external light under normal operating conditions as regards pressure, especially against photo-oxidation and from the subsequent degradation of products occurring under the influence of photo-catalysis.
[0016] In a preferred embodiment of the present invention, the plastic is PET. This choice of material has several advantages indeed in the applications that are relevant to the invention, including a great flexibility of designing and shaping the container and a more reliable formation of the neck region of it, which makes it possible to drink straight out of the bottle without any problems.
[0017] In a particular embodiment of the present invention, the additives used are polymeric substances. As a result, the containers can be made with a nacreous effect, which ensures that a large part of the incident light is automatically reflected by its surface. In addition, the walls of the container have a large measure of internal refraction. These two phenomena—reflection and refraction—jointly ensure a considerable barrier to the penetration of light, which is desirable in the case of light-sensitive products such as UHT milk. The latter can therefore be kept reliably over long periods even under normal conditions, i.e. at room temperature and in the presence of light, without needing special storage conditions, such as a dark or cool place. A significant improvement is thus achieved over the existing PET structures, because the former are particularly suitable for keeping the products at a normal temperature, which is especially advantageous in the case of containers used for packaging UHT milk, which are kept at room temperature. Another advantage is that the well-known white pigment, which is more expensive, can be replaced by a low percentage of cheaper polymeric additives, which reduces the cost.
[0018] In a specific embodiment of the present invention, the additives are thermoplastic polymers. An excellent opacity may be achieved in the outside wall of the preform in this way, and the base material, generally PET, has a higher T g and T m value than the additive admixed to it.
[0019] In a further embodiment of the present invention, the additives are polyolefins. The advantage thereof is that this material is incompatible with the primary base material (PET), their refractive indices being very different from that of PET. When two polymers with different refractive indices are mixed together, they produce a white mixture.
[0020] In a preferred embodiment of the present invention, said additive is polypropylene (PP). Indeed, this material is easy to disperse, especially in PET, which makes it useful when converting the preform into the container.
[0021] The present invention makes it possible to obtain a satisfactory opacity in the outer wall by admixing the above thermoplastic polymeric additives to PET in a ratio of 1:10 in terms of percent by weight. The remarkable thing is that the change to white occurs already with a very little additive of up to only 2%, which is far less than the amounts used in the prior art. On the other hand, when the polymeric additives are present in a fairly high percentage, problems arise with the structure in the form of possible delamination due to incompatibility between the components of the mixture, so that it is preferable to use percentages that do not exceed the critical limit of 10% or even 8%, whereby satisfactory mechanical properties of the mixture are maintained, and a satisfactory barrier effect is ensured at the same time. In a special embodiment of the invention, these additives are introduced into polyethylene terephthalate in an amount of 3-9%, and especially 5-8 wt-percent, which further reinforces the effect mentioned above. A particularly notable advantage here is that it is possible to achieve opaque PET containers whose walls are white and opaque, i.e. have a high colour density without the addition of a white pigment, the colour density being a measure of opacity.
[0022] Another notable special advantage obtained according to the invention by adding polypropylene is that it considerably improves the intrinsic viscosity (IV) of the processed preform material in comparison with that of conventional, mineral-filled PET. The intrinsic viscosity is a measure of the ease with which the preform can be processed in a stretching and blowing device that converts it into the final container. Opaque preforms with quite a large amount of pigment have significantly lower intrinsic viscosity than ordinary preforms, so they lack the required strength in the melt form during the blowing process. This makes it more difficult to stretch and blow the preform into a bottle with the required properties, especially the required wall thickness distribution.
[0023] By contrast, the preforms with added polypropylene instead of added pigments have a high intrinsic viscosity and a high strength in the molten state, so they are much easier to process in conventional stretching and blow-moulding machines. The direct result of this is that containers with a much lower weight can be manufactured with polymeric additives than with large amounts of pigments according to the standard prior art. Since the density of polypropylene is 30% lower than that of PET, the PET-PP mixture is lighter, and the weight of the container is less as well. So both the preforms and the containers obtained in this way are much lighter than the conventional ones.
[0024] A PET structure has recently been introduced that consists of a single layer of an opaque white PET layer but with a fairly large amount of pigment, namely titanium dioxide or zinc sulphate. The disadvantage of this structure is that a relatively large pigment charge of up to 8% is necessary, which is a drawback in Injection moulding. Another undesirable effect occurs in the heating of preforms and their blowing into containers. Furthermore, the protection from light achieved here is unsatisfactory. Finally there is an adverse effect on the cost.
[0025] Some other known polyethylene packaging units have a three-layer structure with a light-barrier insert provided by a black polyethylene layer in between two white polyethylene layers, one on either side of it. A six-layer structure is also known, which is formed by placing the following layers one over the other: a white polyethylene layer, a black polyethylene layer, an adhesive, an ethylene—vinyl alcohol (EVOH) copolymer layer, another adhesive layer, and finally again a black polyethylene layer, the aim being to provide a barrier to both light and oxygen. A three-layer PET structure consisting of a black PET layer between two white PET layers is also known. In an interesting embodiment of the invention, the polymeric additive is incorporated in such a multi-layer structure having a black PET middle layer. Thanks to this measure, virtually all transmitted light can be excluded. So the combination of this polymer addition technique with a central black PET layer in a multi-layer structure has a certain effectiveness.
[0026] However, the disadvantage of especially the first two structures and to some extent of the last of the above structures is that the amount of white pigment incorporated in the outside layer must be quite large in order to prevent the black colour of the middle layer shining through. The fact is that this would cause a colour shift of the bottle surface to grey, which would leave a visible trace at the outer wall which is visible to the consumer. This smudging is most undesirable. To avoid this, the containers must be made with a white outside wall that is thick enough to screen the inner black layer completely in order to make it virtually invisible. However, this makes the bottles relatively heavy and expensive, as well as difficult to blow, since the white pigment must be used in quite a large amount.
[0027] According to an advantageous embodiment of the present invention, a preform with a multi-layer structure is thus proposed with a white PET intermediate layer.
[0028] In another embodiment of the invention the preform contains a certain amount of fragmented metal in the above mixture, especially in powder form and preferably in the form of very small particles having a high dispersibility, so that the metal powder can be homogeneously distributed, the quantity used being especially about 2% and preferably not exceeding 1%. A useful advantage of this is that the resulting containers are considerably more recognizable, due to the presence of metal in them. This makes it easier to sort the containers when they are being recycled. In addition, the containers can also be coded in this way.
[0029] It is also possible here to achieve a particularly remarkable mirror effect on the inside of the wall of the container. This increases the number of possible applications of the containers with a light-barrier effect to include tubes for toothpaste and other cosmetics and for flowing foods such as mayonnaise and ketchup, the containers then having a semi-rigid wall, in addition to the containers with a rigid wall mentioned above.
[0030] According to a further preferred embodiment of the invention, the preform comprises a certain amount of iron-containing metals, especially stainless steel, the magnetism of which is useful when it comes to recycling.
[0031] Alternatively, the preform contains a certain amount of non-ferrous metals in the mixture mentioned above.
[0032] According to a further remarkable embodiment of the invention, the surface of the PET containers can be transformed by changing the nacreous appearance to a metallized one, especially a silvery metallic appearance, by suitably incorporating additives during the blowing of the preforms into containers. The metallized appearance of the surface can be attributed to additional incompatibility between the two polymers, which in turn is due to the stretching of the material in the cold, which makes the nacreous surface additionally turn white, which nacreous effect then makes disappear it or reduces it, creating a mirror-like metallic appearance on the processed product.
[0033] The present invention is also related to a process for making opaque containers, including multi-layer polyester containers, by injection-moulding opaque preforms and by co-injection, followed by blowing the preforms to containers.
[0034] This involves the preparation of an immiscible composition that is naturally white, i.e. white without any pigments. The immiscibility is manifested in the orientation of the preform when it is being blown into a container, since the surface of the material is changed from having a white appearance to having a nacreous one, at least in the regions where the preform is stretched.
[0035] The light transmittance data can be further improved by adding a small amount of colourants to the PET/PP mixture, typically about 2-4 wt-% or about 5-8 wt-%, according to whether the container has a multi-layer or a single-layer structure, respectively. This yields results which are directly visible to the naked eye.
[0036] According to an additional remarkable embodiment of the invention, both the nacreous and the metallized finishes can be coloured by changing the white base either by adding coloured PP pigments to it, or by using a coloured intermediate layer in the case of a multi-layer structure.
[0037] Further features and properties of the preform, the container and the process will emerge from the following description of some embodiments of the invention, which are illustrated with the aid of the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1 shows a diagrammatic cross-section of a preform, taken along its longitudinal axis according to a first embodiment of the invention.
[0039] FIG. 2 shows a diagrammatic cross-section of a preform, also taken along its longitudinal axis according to a second embodiment of the invention.
[0040] FIG. 3 represents a front elevation of a first embodiment of a container according to the invention.
[0041] FIG. 4 is a front elevation of a further embodiment of a container according to the invention.
[0042] FIG. 5 to 9 show a first set of graphs based on measurements of the light-barrier properties and some related parameters.
[0043] FIGS. 10 to 21 show a second set of graphs based on measurements of the light barrier properties and some related parameters in the case of single layer preforms represented in FIG. 2 .
[0044] FIGS. 22 to 24 show a third set of graphs based on measurements of the light barrier properties and some related parameters in the case of multilayer preforms represented in FIG. 1 .
DESCRIPTION
[0045] This invention here is generally involved with preforms and containers which are opaque and intended for containing products that are sensitive to radiation and especially light, such as milk, dairy products, fruit juices and so-called functional drinks with nutrients, which can thus be effectively protected from photo-oxidation and from the degradation of the contents based on photo-oxidation.
[0046] FIG. 1 shows a preform 10 with a wall 7 and a neck 8 in cross-section taken along the longitudinal axis l. This is a three-layer structure consisting of a base material which is composed of a primary plastic, which forms an outer layer 1 and an inner layer 3 , with an intermediate layer 2 between them, consisting of a secondary plastic. The primary plastic is advantageously polyethylene terephthalate, and the secondary plastic may also be polyethylene terephthalate. The primary base layer has a whitish and opaque appearance, so it reflects a large part of the incident radiation, especially light when it impinges on the wall as shown by the arrow y 1 . The outer layer 1 is made opaque by adding a thermoplastic polymeric additive 5 to PET in an amount of even only from 1 wt-% upward, shown here by cross-hatching. The outer layer 1 therefore forms an effective light barrier, the light-blocking effect whereof can be further increased if need be by the intermediate layer 2 which is downstream.
[0047] Said thermoplastic polymeric additive 5 is preferably polypropylene. It can be mixed with PET in an amount of 1-10 wt-%, if required 5-8 wt-%.
[0048] In one of the examples, the intermediate layer 2 containing polypropylene can be completely black, so that any rays that may have traversed the outer layer 1 of the preform are absorbed by the intermediate layer 2 , which has a high radiation-absorbing capacity and acts as a downstream radiation filter having a virtually total radiation blocking function, so that virtually no rays can penetrate past the intermediate layer 2 , as a result of which the content of the container is no longer attacked by external radiation. This is indicated schematically in FIG. 1 by the arrows y 1 and y 2 , respectively.
[0049] This embodiment is particularly useful when the preform is to be blown into a container and especially into a bottle for UHT milk. In this case, the intermediate layer 2 also acts as a gas barrier, in addition to excluding the light by absorbing it, whereby the oxygen penetrating from the outside is therefore also absorbed by it, in such a way that the milk is not attacked by said outer oxygen particles. This gas barrier effect is therefore combined here with the light barrier action of the outside and inside layers 1 and 3 .
[0050] The general advantage of a multi-layer structure is that undesirable external substances that may penetrate through the outside layer 1 are finally fully blocked by the intermediate layer 2 , acting as an exclusion barrier, which provides extra safety.
[0051] To optimize the structure, the intermediate layer 2 can be changed from black to grey with the aid of polypropylene or to other colours that are supported on grey with the aid of polypropylene, in order to ensure the same maximum light exclusion.
[0052] The amount of additives 5 in the intermediate layer 2 can be increased to very high levels compared with the usual situation, because the intermediate layer, with e.g. only about 10% of the total thickness, does not affect the mechanical characteristics of the container and so it does not influence either the blow moulds used for the preforms or the co-injection thereof. These characteristics mainly come from the inside layer 3 and the outside layer 1 , which jointly make up about 90% of the three-layer structure 10 .
[0053] Furthermore, a plurality of other colouring additives and colourants can be incorporated in the intermediate layer 2 more easily than in the customary situations with PET, because one can use lower injection temperatures for the intermediate layer than for the outside layer 1 and the inside layer 3 . This opens up a very wide range of possibilities for the incorporation of other and/or more additives, particularly in the intermediate layer, which would not be possible with preforms having a single-layer structure.
[0054] With a paler colour for the intermediate layer, a smaller amount of colouring additives is needed in the outside layer, which has a covering function, because a paler colour is easier to hide by a white outside layer. This has a quite favourable effect by reducing the cost and improving the ease of blowing the preform 10 . It is therefore possible to use opaque preforms with a thick wall, which would not be possible otherwise under normal conditions.
[0055] In addition, the colour of the intermediate layer 2 and the colour of the outside layer 1 can be blended and adjusted to each other if the required colour of the outside surface is not white, such as blue, red, gold, yellow or orange, etc. Such situations can mainly arise from the marketing requirements for the recognizability of said containers, in which PET is a good base material because it offers numerous possibilities in this respect, including a great variety of designs and shapes for the containers. The colour combination mentioned above can be utilized to the utmost by making the outside layer 1 transparent but coloured, thereby providing further options by using any possible colour combination required. This also improves the light barrier properties.
[0056] The following examples illustrate the further improvements in the barrier properties of the container wall, not only for light but also for oxygen. An additionally improved oxygen barrier that goes beyond the ordinary PET can be incorporated for the packaging of oxygen-sensitive dairy products that contain basic nutrients such as vitamins, proteins, carbohydrates, starches, essential fatty acids, etc. This can be achieved by incorporating in the intermediate layer 2 materials with improved barrier properties, such as aromatic or aliphatic barrier plastics, nylon and aromatic polyesters such as for example:
[0057] polyethylene 2,6-naphthalate (PEN)
[0058] polyethylene terephthalate ionomer (PETI)
[0059] polyethyleneimine (PEI)
[0060] polytrimethylene naphthalene 2,6-dicarboxylate (PTN) and
[0061] polyethylene terephthalate—polyethylene naphthalate copolymer (PETN).
[0062] Alternatively, the same aim can also be achieved by adding an oxygen scavenger, such as an oxidizable polyester or an oxidizable nylon.
[0063] This may further best be achieved by incorporating both a material with improved barrier properties and an oxygen scavenger, so that the inside of the container is protected not only from light but also from oxygen.
[0064] In this way, the incorporation of polymeric additives in the PET base material in combination with the additional use of colour additives in both multi-layer and single-layer structures can give rise to a great variety of combined colour effects that not only ensure the technically desirable light barrier properties but also offer visual advantages facilitating the identification of the product.
[0065] On the other hand, a single-layer structure 40 is satisfactory for some applications in the dairy sector, especially for products derived from milk, where the degrading action of oxygen is less critical. Said single-layer structure is shown in FIG. 2 . Any colour can be used in these applications, and a single-layer milk bottle can be made by the addition of the required coloured pigments and colouring materials.
[0066] FIG. 3 shows the front view of a container of the bottle type 20 obtained by stretching and blowing a preform 10 or 40 of the type shown in FIGS. 1 and 2 . The outer wall 21 is visible and has a special appearance 22 indicated here by light stippling. This remarkable effect is caused by a nacreous appearance 22 that the bottle 20 presents to the consumer, making it not only particularly attractive but also easier to recognize. The nacreous effect is promoted by the biaxial stretching of the preform, i.e. its stretching both in the radial and in the longitudinal direction, and by the blowing of the preform to form the container. This nacreous effect is is achieved from the delamination occurring in the mutually joined but immiscible primary base materials and polymeric additives, wherein their immiscibility is in turn due to their mutual incompatibility. It is therefore the choice in full awareness of incompatible materials as constituents of the plastic mixture which creates surprising nacreous effects.
[0067] This nacreous effect 22 is not only an advantage in the presentation of the product but also serves a technical purpose by making the resulting outer surface 21 quite reflective. The resulting surface therefore already has one of the three fundamental properties characterising a light barrier, which are low transmittivity, high absorptivity and high reflectivity.
[0068] What is ingenious here is that this nacreous effect 22 produces a white gloss if a special polymer is chosen and mixed with PET. Satisfactory barrier properties may be obtained even without the addition of any colouring matter, notably a white one. The whitish pale nacreous appearance 22 can therefore be obtained by stretching the plastic without the use of any colouring matter though.
[0069] The barrier properties can yet be further promoted by the addition of a small amount of colourants, typically about merely 24 wt-%, or about 5-8 wt-%, according to whether the container has a multi-layer structure or a single-layer one. This is a considerable advantage from the technical point of view, since the addition of colourants causes problems when a preform is being blown into a bottle. The more pigment it contains the more difficult is the blowing process. The critical value set above at 8% for coloured pigments is a threshold value beyond which the blowing of preforms into bottles becomes considerably difficult.
[0070] It has been shown experimentally that the wall 21 can reflect up to 92% of incident light even without the use of colourants, but by incorporating polymeric additives alone, which is more than sufficient for a wide range of applications, such as sleeve bottles, where the printed sleeve can be drawn with virtually any pattern on such a container. This is therefore a fundamental characteristic which is proper to the present container.
[0071] An additional advantage lies in the easier blowing of the preform to a container, owing to the possible absence of coloured pigments, which make blowing only difficult. Furthermore, the mechanical properties of the material are not diminished here as they inevitably are when colourants are added. In addition, the thermal stability of the preform is better, so the latter remains stable at considerably higher temperatures.
[0072] In addition, the absence or at least greatly reduced presence of pigments, which are relatively heavier than polymeric additives, means that the container formed is very light, being a reduction up to 20 wt-% lighter, while retaining a reflective index of more than 92, together with the possibility of using the customary blowing equipments.
[0073] However, an improvement in the light barrier properties for a multi-layer structure in comparison with a single-layer one cannot be expected if no colourants are incorporated in it. So the use of a multi-layer structure is only sensible if colourants are present. In the absence of colourants, the cheaper single-layer structure will suffice. For structures of this type, such as that shown in FIG. 2 , pigments are therefore used in relatively small amounts, yet without exceeding the critical threshold value for blowing.
[0074] Further thermoplastic polymeric additives are formed by polyethylene additives, in particular so-called high-density polyethylene known as HDPE, low-density polyethylene (LDPE), medium density polyethylene (MDPE) and linear low density polyethylenes (LLDPE). Further to be considered are polyolefine acetate co-polymers, such as methyl (EMA), ethyl (EEA), vinyl (EVA) acetate, polyethylene co-polymers of vinyl alcohol (EVOH).
[0075] Polystyrene (PS), polyvinylchloride (PVC), polyethylene-terephthalate (PET), polyethylene-isophthalate (PEI), polybutylene-terephthalate (PBT), polyethylene-naphthalate (PEN), polytrimethylene-naphthalate (PTN), polytrimethylene-isophthalate (PTI), polytrimethylene-terephthalate (PTT), phthalic acid copolymers, polycarbonate (PC), acrylonitrile butadiene styrene (ABS), polyamide 6 (PA6), polyamide 66 (PA 6,6).
[0076] FIG. 4 shows a variant of the bottle 30 , where the darker shaded zones 31 indicate a metallized appearance 32 of the container.
[0077] Said nacreous effect 22 , resp. metallized effect 32 , which are due to the addition of a polymeric additive to the primary base plastic, have the intrinsic advantage for light-sensitive products, such as UHT milk, that the surface 21 or 31 of the container 20 and 30 containing the milk reflects a substantial proportion of the incident light in a natural way. In addition, the wall of the container has a great deal of internal refraction. These two phenomena mutually combine to reduce or even prevent the penetration of light.
EXAMPLES
[0078] In a typical comparison, a one-litre multi-layer bottle with the structure white PET -black PET—white PET weighs 26 grams when made with polymeric additives according to the invention and 32 grams when made by the traditional technique using a large amount of pigment, which means an approximately 25% saving of material, i.e. a considerable amount.
Experiments
[0079] Said light barrier properties and said associated three parameters—transmission, absorption and reflection—were determined experimentally by means of a spectrophotometer of the “datacolour” type 650™ customarily used for this purpose, and the data obtained were used to construct the graphs shown in FIGS. 5-9 .
[0080] The graphs in FIGS. 5 and 6 show the transmission of radiation that is incident on the container as a function of its wavelength λ in the case of a single-layer structure containing 5% of polypropylene in the first case (see FIG. 5 ) and a structure containing 10% of polypropylene in the second case (see FIG. 6 ). In the case of light transmission, FIG. 5 shows that an extremely strong light-blocking effect is observed when polypropylene additives are added to PET as the primary plastic without any colour additives or colourants. In FIG. 6 , which shows the reflection, the high reflectivity can be observed, which is caused by the nacreous appearance of the wall surface of the container after stretching the original PET/PP preform thereto.
[0081] FIGS. 7 and 8 similarly show the transmission and reflection of multi-layer structures made with the addition of 10% propylene additives and further with the addition in the amount of 2% of a white colourant in the outside layer 1 and with 2% of a black colourant in the intermediate layer 2 . Both FIGS. 7 and 8 indicate the great effect on the transmission which is generated by the incorporation of a black layer as intermediate layer, ensuring the total exclusion of light. As to the reflectance shown in FIG. 8 , the reflecting effect of the nacreous outer surface of the wall can be observed, just as indicated in the case of the one-layer structure represented in FIGS. 5 and 6 , and partly by the internal refraction of light.
[0082] Measurements carried out on single-layer bottles indicated that the transmitted light is reduced to only 5%, which is an excellent result compared with PET, which is not completed with polypropylene additive and without white colourants, as set out hereafter, especially in connection with FIGS. 10-11 .
[0083] If the container is only made of the primary plastic PET, one could observe that up to about 90% of the light is transmitted.
[0084] FIG. 11 refers to the case when 2% of additives in the form of polypropylene is added to the primary base material. It can be concluded from this graph that even such a modest amount of polypropylene additives causes a significant reduction in the amount of light allowed through.
[0085] It can be observed on FIG. 12 showing the addition of polypropylene up to 5% that the light rays transmitted through the container wall are further limited to 15%.
[0086] It can be deduced from FIG. 13 that a light transmission is limited to merely 5% when adding the same additional amount of polypropylene additives of 5% yielding a total amount of 10% PP. It is thus striking that the light exclusion is not linear with the addition of polypropylene additives, but instead decreases relatively faster. For example, one may state when comparing FIGS. 11 and 13 that five times more additives correspond to ten times less light transmission. A conclusion here is then that the adding of polypropylene additives up to 10% makes the light transmission decrease by 95%, which is thus a quite remarkable result.
[0087] A further group tests shown in FIG. 14 to 17 is set out hereafter. In this group 5% polypropylene additives are respectively added to the primary base material PET, with a further addition of white colourants in an amount comprised between 2% and 8% respectively, with each time an increase of 2%, i.e. 4 and resp. 6% white. The graphs in FIG. 14 show that the addition of 2% colourants reduces the transmission of light rays to approximately 2%, while in the addition of colourants is doubled to 4%, the transmission of light is reduced by half to approximately 1% as appears from FIG. 15 .
[0088] Multiplying colourants by three times up to 6% causes a further reduction of light to merely approximately 0.3% as shown in FIG. 16 .
[0089] FIG. 17 shows the maximum addition of white according to the present tests in the amount of 8% with a light transmission reduced to approximately merely 0.15% of the incident light.
[0090] It can therefore be deduced from the four preceding test series that the further addition of white colourants by 2% reduces the light transmission from 15% as shown in FIG. 12 to merely 2% as shown in FIG. 14 . With regard to this, a moderate addition of white colourants is able to reduce the light transmission to a very low level of only 0.15% light transmission.
[0091] Similarly as in the preceding tests series which are represented In FIG. 10 to 13 , it can be stated again that the reduction of light transmission is not linear in function of the addition of colourants since multiplying the colourants by four from 2 to 8% generates up to approximately 13 times more light transmission, which can be considered as a remarkable result as well.
[0092] A still further series of four tests represented in FIG. 18 to 21 is set out hereafter. These tests take place in quite similar conditions, under doubling however of the added percentage of polypropylene additives from 5 to 10%.
[0093] FIG. 18 shows a graph of transmittance in % in function of the wavelength of the incident radiation, wherein it may be observed that adding 2% of colourants with a doubled addition of polypropylene additives to 10%, transmits only approximately 1% of the incident light radiation, i.e. the half of the transmittance under similar conditions, with the addition of the half of polypropylene additives to 5% however, as shown in FIG. 14 .
[0094] The subsequent FIG. 19 to 21 are similar representations with each time 2 additional percents of colourants addition. With the first doubling of the colourants to 4% represented in FIG. 19 , there is still only 0.4% light transmission. When tripling the colourant addition white to 6%, the graph represented in FIG. 20 shows that the light transmission is still further reduced by half to 0.2% of the incident light radiation.
[0095] Finally when multiplying by four the white colourant addition to 8%, the light transmission is reduced to only 0.1% of the incident radiation as shown in FIG. 21 .
[0096] A comparison of the test results within this additional group of measures represented by FIG. 18 to 21 teaches again that the reduction of light transmission is not linear with the increase of colourants, but with a certain acceleration effect with amplifying reduction of the light transmission with respect to the addition of colourant additives.
[0097] Consequently, it can be deduced from the latter series of measurements that the graphs appear two times lower compared to the previous series measurements with the half of polymer additives, i.e. 5% PP, including in the presence of white colourant, when further adding polypropylene as polymer additive up to 10%.
[0098] At last, a last series of measurements is represented in FIG. 22 to 24 showing analogue graphs, each time with colourant additives in the amount of 8%, the first one whereof in FIG. 22 in the absence of polymer additives, which means only with colourant additives, whereas the two subsequent figures represent graphs each time with the addition of 5% polymer additives, i.e. 5% polypropylene in FIG. 23 , resp. 10% polypropylene in FIG. 24 .
[0099] FIG. 22 lets light radiation through up to approximately 1%, whereas the addition of merely 5% polypropylene transmits light radiation up to merely 0.15% of the incident light radiation. When doubling polypropylene to 10%, the light transmission is limited to approximately 0.1% as shown in FIG. 24 .
[0100] Both latter FIGS. 23 and 24 correspond logically with FIG. 17 and respectively 21 above. It can be deduced from these figures that the addition of white colourants without polymer additives may cause up to 1% light transmission at a wave length of 550 nm, but not less. Only the addition of polymer additive polypropylene may bring back the graphs to a level up to 0.1%, which is extremely low. Lower levels of colourant additions white with polymer additives reproduce the same performances as observed in FIG. 10 to 21 .
[0101] It is to be noted here that these measurements were carried out by means of a spectrophotometer which is a worldwide recognised device which provides extremely reliable measurement results, so that the tests set out above should be considered as particularly relevant. All abovementioned tests were carried out with each time the same bottle.
[0102] Besides, only the transmitted light radiation getting through the container wall was measured, since only this amount of radiation is detrimental for the product which is to be contained in the container. The results set out above should further be related with respect to admissible radiation transmission values in the intended field. In view thereof, it should be considered that when the product to be contained is milk, the maximum admissible transmission value amounts to 0.3%. In other words, this means that for milk preforms the addition of colourants is suitable in the amount of 6% in case 5% polymer additives are added as represented in FIG. 13 . In case for instance 10% polymer additives are added, the amount of white colourants may be reduced to a percentage which is comprised between 4 and 6, e.g. approximately 5% of white colourants, as may be assumed by extrapolating the measurement results of FIG. 19 , resp. 20. This is a remarkable result in the meaning that blowing a preform becomes more difficult as more colourant additives are added. The difficulty of blowing becomes critical, especially as from 4% addition of white colourants and more. It is to be noted here that the performance of the blowing machine may decrease up to 20% and more. In addition, one is also limited in the geometry of the preform because the wall thickness thereof will be smaller than 4 mm, and even up to 3.5 mm.
[0103] When further also considering the costs of white colourants such as titanium dioxide or zinc oxide, the usefulness of a minimum addition of white colourants will be appreciated directly. In this respect, it may be stated that very favourable transmission results may be achieved without the addition of colourants. Example of applications in this respect are a maximum value of 0.7% transmission, which is not enough for the filtering of light for some kinds, in particular UHT milk where 0.3 is the maximum transmission.
[0104] When adding an amount reduced by half of white colourant additives of the UHT type for the same amount of added polymer additives of polypropylene, i.e. 5%, a light transmission of 2% is achieved.
[0105] It can further be observed that the colourants will have a more efficient behaviour regarding light exclusion in the presence of polymer additives of polypropylene. It can therefore be stated that the polymer additives have a synergetic effect on colourant additives.
[0106] It can further be observed on most of the graphs that they present an increasing profile in function of the wavelength, whereby it may be stated that the smaller the wavelength of the incident radiation, the easier the incident radiation may be blocked by the container wall.
[0107] It is particularly worth noting that the multi-layer structure of the container according to the invention can also be used with an intermediate layer 2 that is similarly white instead of being black. The replacement of the latter by the former according to the invention is possible here thanks to said synergistic effect of the polypropylene-type polymeric additives and colouring additives, ensuring an additional intrinsic light-blocking effect for enabling the achievement of this blocking mode of the intermediate layer 2 without the need of a black intermediate layer with its characteristic light-absorbing function. This also has the outstanding advantage that owing to the invention, the black intermediate layer no longer needs to be covered by a white outer layer as in the conventional types of preform. Achieving this quite remarkable effect is only possible by subjecting the initial preform, i.e. the semi-finished product to biaxial stretching in order to obtain the container as the finished product. It is therefore possible to achieve the absorption of the radiation without any pigmentation, i.e. without the addition of colouring additives that are needed for obtaining an absorbing black intermediate layer, but not for a white light-blocking intermediate layer. A similar effect may be obtained without adding colouring additives or pigments, yet by subjecting the initial preform to biaxial stretching in order to form the container. Owing to this method of biaxial stretching, a crystalline structure is achieved in the polyethylene terephthalate, as a result of which the biaxially stretched container becomes white.
[0108] It is therefore possible now to produce a coloured container like a bottle with three layers or more generally a multi-layer structure, by adding a relatively small percentage of colourants or pigments with a suitable incorporation of polymeric additives according to the invention.
[0109] It should further be mentioned that it is rather difficult to load PET. Indeed, incorporating additives like pigments and colourants in PET is relatively difficult because the processing temperature used here is high, i.e. from 250 to 300° C., which is undesirable for pigments and colourants. In addition, the pigmentation of PET is much more expensive than that of other plastics. In this respect, there are pigments allowing higher levels of charges, such as e.g. HCAe used in the tests mentioned above. The same light exclusion effect can therefore be obtained here but at a lower cost. However, a multi-layer structure must be used to reduce the transmission to an absolute minimum, i.e. practically to zero.
[0110] Owing to the invention, light radiation is absorbed instead of being refracted, and this is achieved merely by using polymeric additives, i.e. with very small pigment or colourant charges or even none at all.
[0111] To summarise, multi-layer bottles can be advantageously made with a lower weight and so a lower cost. Another advantage is that the injection moulding and blowing process used here is equivalent as with customary single-layer PET structures, which is not possible with conventional systems. Yet another advantage of the present invention is that the surface of the containers has a nacreous appearance. This is a particularly remarkable effect, which consumers find very attractive.
[0112] Furthermore, none of the existing structures mentioned above can ensure an additional oxygen barrier effect over and above that obtained with conventional PET containers, at least for the packing of products that are sensitive to both light and oxygen. In regard thereof, a still further advantage of the invention is that an oxygen barrier can be incorporated in the walls of the container or preform by replacing polyethylene terephthalate in one or more of the layers by a polyester barrier that absorbs oxygen. | Preform, serving as a semi-finished product, for a container intended for containing products therein that are sensitive to radiation in particular light sensitive and food and dairy products, consisting of at least one base layer ( 1 ) made of a primary plastic base material, with a certain amount of additives ( 5 ) incorporated in it ( 1 ), characterised in that said preform ( 10, 20 ) is opaque over virtually the whole extent thereof, wherein a relatively low percentage of plastic additives ( 5 ) is incorporated to generate sard opaque appearance ( 22 ), so as to protect the inner space ( 9 ) thereof which is delimitated by it against external radiation (V 1 , V 2 ) particularly electromagnetic radiation, more particularly light, under normal pressure condition. | 50,934 |
FIELD OF THE INVENTION
The present invention is directed to a suspension system for a pipe lining machine and more particularly, to a damping assembly for damping vibrations in the belts used to support and rotate pipes during the lining operation.
BACKGROUND OF THE INVENTION
Concrete-lined pipes of exceptionally large diameter are generally used as buried conduits for conducting drinking water, irrigation water, and other fluids. To construct such a pipe, concrete mortar is placed inside a steel pipe which is then spun to centrifugally distribute the concrete mortar in an even thin layer on the inside wall of the pipe.
A machine, generally known as lining machine, is used to perform the operation and basically consists of multiple belt assemblies, usually three to five, which are spaced apart for supporting the pipe along its length. A side view of a pre-existing lining machine 10 is illustrated in FIG. 1 . The side view shows the typical belt arrangement for each belt assembly of the lining machine. Each belt 12 is formed into a loop which wraps around a set of four pulleys, as depicted in FIG. 1 .
The pipe is supported by the belts at the portion between the two upper pulleys 14 , 16 . The left upper pulley 14 is generally fixed in position and powered by a drive motor to provide the necessary drive force to spin the pipe at sufficient rotational speeds to adequately pack the mortar on the inside wall of the pipe. The right upper pulley 16 can be adjusted toward or away from the left pulley before the spinning operation to adapt the machine to a range of pipe sizes. The right lower pulley 20 may also be adjusted. The left lower pulley 18 is fixed in position. All pulleys are fixed in position during operation.
To mortar line a pipe, the pipe is initially rotated at a steady but relatively low speed and a mortar feeding lance is moved inside the pipe to pour the mortar material along the length of the pipe. The pipe is then accelerated to a desired rotational speed to pack the mortar against the internal pipe wall for a sufficient period of time to allow the mortar to dewater.
Due to the elastic property of the belts, the generally uneven roundness of the pipe, and the imbalance in the pipe caused by an uneven mortar thickness caused by the rotation of the pipe around its mass (i.e., gravity) center, the pipe vibrates on the belts while it is rotating. The pipe and the belts together constitute an oscillating system with a particular frequency of its own, its so-called “natural frequency.” When the pipe is rotated at high speeds, the reciprocating movements of the belts come into the natural frequency range of this system. When this happens, the pipe and belts tend to move independently of the motion imparted to them by the drive motor.
The vibration of the system is especially large when in the natural frequency of the system before reaching the packing speed. If the pipe is excessively out of balance, the vibration can be very severe and the pipe can bounce off of the belts, causing the belts to slack and sometimes slip away from the pulleys. This damages the belts and may also cause the pipe to fall off of the machine, thereby creating a dangerous situation for both the equipment and human operators of the lining machine.
Accordingly, it would be desirable to provide means for dampening the vibration of the system during the spinning operation for the safety of the machine and its operators.
SUMMARY OF THE INVENTION
According to one embodiment of the invention, a pipe lining machine including several belt assemblies for supporting a pipe to be rotated is provided. The pipe lining machine also includes a base, a drive motor, and several connecting arms for each belt assembly. The connecting arms are connected at a bottom end to the base. At least one of the connecting arms per belt assembly is hingeably connected to the base. Each belt assembly includes several pulleys, each connected to the top end of each of the connecting arms. The pulleys include a drive pulley operatively connected to the drive motor and a movable pulley connected to the connecting arm hingeably connected to the base. A belt formed into a belt loop is wound around the pulleys. An interior surface of the belt loop contacts the pulleys and an exterior surface of the belt loop supports a pipe to be rotated. Means are provided for damping movement of the movable pulley.
According to another embodiment, the means for damping movement of the moveable pulley is a damping assembly operatively coupled to the moveable pulley. Preferably, the damping assembly includes a pneumatic suspension member, e.g., an air bellows, coupled to the moveable pulley, and a hydraulic damping member, e.g., a hydraulic cylinder, coupled to the moveable pulley and to the pneumatic suspension member.
DESCRIPTION OF THE DRAWINGS
This invention may be better understood and its numerous objectives and advantages will become apparent to those skilled in the art by reference to the following drawings:
FIG. 1 is a side view of a pre-existing pipe lining machine;
FIG. 2 is a plan view of a pipe lining machine according to one embodiment of the invention; and
FIG. 3 is a side view of the pipe lining machine shown in FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 2 illustrates one embodiment of the invention, which includes two pairs of belt assemblies adapted to support a pipe such that it is free to rotate. A pair of the belt assemblies is typically positioned on either end of the pipe. Only one pair of the belt assemblies is illustrated in FIG. 2 . The other belt assemblies are substantially the same in their construction, mounting, and operation. Hence, the separate parts herein indicated by reference as applied to the pair of belt assemblies 30 , 32 are equally applicable to the other pair of belt assemblies (not shown).
Each pair of belt assemblies share a common base 34 (FIG. 3 ). Each belt assembly includes a belt loop 36 wound around four pulley pairs: left upper 38 ; right upper 40 ; left lower 42 ; and right lower 44 . Power is applied to rotate a power pulley, in this embodiment the left upper pulley 38 , to thereby rotate the belt and thus the pipe. Each of the belt assemblies will have the same corresponding power pulley. The locations of the axles of the power pulleys are fixed relative to the base. Preferably a 150 hp drive motor (not shown) is used to drive the power pulley in each of the belt assemblies. A preferable drive motor is capable of rotating pipes weighing up to 20 tons, which may rotate at speeds up to 100 mph at the pipe edge when at the packing speed.
The pair of right upper pulleys 40 are rotated on a common axle 45 which is mounted in an adjustable pulley supporting arm 46 . The adjustable pulley supporting arm 46 is adjustable at its upper and lower ends to accommodate pipes of different size on the belt loop 36 . The upper end of the adjustable pulley supporting arm 46 is attached with pins to one end of a connecting bar 47 . At a point spaced from that one end, the bar is also connected to the upper end of a pedestal 48 built on the base 34 . The connecting bar 47 can be connected to the upper end of pedestal 48 with a pin through one of a series of holes along its length to adjust the position of the right upper pulleys 40 for relatively minor changes in pipe size.
The lower end of the adjustable pulley supporting arm 46 is hingeably connected to the base. It can be connected to one of the two or more holes 49 provided in the base to adjust for a major change in pipe size. Holes 49 are located laterally along the base at positions that are spaced various distances from the left pulleys.
The left lower power pulley 42 is fixed in position. Each pulley forming the right lower pulley pair 44 is supported by a hinged pulley supporting arm 50 which is hingeably connected at its lower end to the base 34 .
The upper end of each hinged pulley supporting arm 50 , which extends above the pulley, is connected to a damping assembly 52 by a fork-shaped link (or a yoke) 54 . Preferably, each hinged pulley supporting arm is pivotally connected using a pin 59 to a hole 61 in tongue 55 connected to the base 57 of the fork-shaped link. Preferably, the tongue has a series of holes 61 along its length. The pulley supporting arm 50 can be connected to any such hole 61 using a pin. As such, the position of the hinged pulley arm can be adjusted.
Each damping assembly includes air bellows 56 positioned inside a housing 58 . A front end 80 of the air bellows is secured to the housing structure. The housing 58 has a supporting leg 60 extending downward and connected with a pin 51 to an arm 63 extending from the base 34 . Near its upper end, the housing is secured by an eye bolt 53 to another pedestal 62 which is preferably built on the base.
The forked double arms of the link 54 extend around the bellow housing and connect with each end 65 of a shaft 64 transversely secured to the rear end of the air bellows. The shaft ends 65 extend through a slot opening 66 on each of the side walls of the housing. A wheel 68 is mounted at each end of the shaft inside the link and rides in a corresponding one of these slot openings inside the link.
When each bellows is inflated with air pressure, it pulls its corresponding lower pulley 44 via the fork-shaped link and stretches (i.e., tensions) the belt to lift and support the pipe. Before the belt is driven with a pipe in place, the bellows should be inflated with air pressure to a level positioning the shaft wheels 68 midway along the slots 66 . In this regard, the bellows will be able to oscillate as necessary in either direction along the slot 66 . The bellows work as a suspension and tensioning device to take up the belt slack when the pipe vibrates.
A hydraulic cylinder 70 is mounted in an extended housing 72 secured to the rear side of each of the bellows housing 58 . A cylinder rod 74 extending from the hydraulic cylinder is connected transversely to the shaft 64 . The rod is connected on the side of the shaft opposite the bellows. The hydraulic cylinder provides resistance to the movement of the shaft which, ideally, is proportional to the velocity of the force attempting to move the shaft. The cylinder is filled with hydraulic fluid and its ports are connected to a system of control valves (not shown) for damping down vibration. Such valves and their operation are known in the art. One of the control valves is preferably a throttling valve that is set to relieve fluid pressure generated in the cylinder by the movement of the shaft, and thus, decrease the resistance provided by the cylinder when a force equal to or greater than a preselected magnitude is applied to the shaft. This pressure relief setting is preferably set to correspond to a force less than 25% of the pipe weight.
According to a preferred embodiment of the present invention, the hinged lower right pulley 44 moves laterally in response to slack and vibrations in the belt loop 36 caused by the vibrating pipe. As the lower right pulley 44 moves laterally, it moves the fork-shaped link 54 which causes the shaft 64 to move along the slot openings 66 formed on the bellows housing 58 sidewalls. The movement of the shaft and thus, of the lower right pulley, is resisted by the air bellows and the hydraulic cylinder which are coupled on opposite sides of the shaft. The bellows and the hydraulic cylinder resist movement of the shaft and thus, of the lower right pulley, toward the center of the pipe (i.e., the movement compressing the bellows). In other words, the bellows resists the belt detensioning movement of the lower right pulley. Such movement is caused by the weight of the pipe or when the pipe bounces on the belt. When the pipe bounces off the belt, the bellows expands in a direction keeping the tension of the belt on the pipe so as to keep the belt in contact with the pipe.
To mortar line a steel pipe, the pipe is rotated at a steady lower speed and a mortar feeding lance is moved along the length of the interior of the pipe to pour the mortar material into the pipe. The pipe is then accelerated to a desired speed for a sufficient period of time to pack the mortar against the pipe wall and to remove the excess water from the mortar.
As a rule, the pipe is not perfectly round and hence rotates about its mass center rather than its geometric center which results in an eccentric rotation. During rotation of the pipe, the belt itself acts as a low mass spring and responds to high frequency, low amplitude vibrations caused by the eccentric rotation of the pipe. The pipe and the belt together constitute an oscillating system with a particular natural frequency. When the pipe is rotated at high speeds, the reciprocating movements of the belt come into the natural frequency range of this system. The oscillations associated with the natural frequency are experienced along a range of rotational speeds evenly distributed about the rotational speed at which true natural frequency of the system occurs. For example, if the true natural frequency of the system occurs at 50% of the packing speed, the range at which oscillations associated with the natural frequency will be experienced by the system is in the range of about 40% to 60% of the packing speed.
When in operation, the bellows acts as a support for supporting the weight of the pipe. In essence, the belt in combination with the bellows acts as a two spring system with the two springs in series. The bellows can be expanded as necessary by filling with air to support heavier or lighter pipes.
As the pipe rotates and jumps on the belt, the minor vibrations are absorbed by the stretching of the belts. Large amplitude vibrations are absorbed by the bellows. As the impact on the belt by the pipe increases, the larger amplitude vibrations are damped by the hydraulic cylinder which acts as a shock absorber.
It has been found that the action of the air bellows actually lowers the natural frequency of the system. The hydraulic cylinder which acts as a shock-absorbing device further damps the vibration and reduces oscillation at the natural frequency of the system. This results in a smoother ride for the pipe with better lining quality and a longer belt life. This damping action also makes the machine safer to operate. Moreover, the natural frequency of the system is reached at lower rpms. This is advantageous in that it makes it easier for the motor to drive the spinning pipe through the natural frequency of the system. Furthermore, the packing speeds are isolated further away from the rotational speeds at which the natural frequency occurs and hence the system is less affected by the excess vibrations created in the system when near its natural frequency. | A belt assembly for a pipe lining machine used to make concrete lined pipes. A pipe to be rotated is supported on the exterior surface of a belt loop wound around several pulleys, including a drive pulley and a displaceable pulley which moves laterally in response to slack and tension in the belt loop. A damping assembly is connected to the displaceable pulley to damp vibrations in the displaceable pulley. Preferably, the damping assembly includes a pneumatic suspension member, e.g., air bellows, and a hydraulic damping member, e.g., a hydraulic shock-absorbing cylinder, connected in series to the displaceable pulley. | 15,196 |
FIELD OF THE INVENTION
The present invention relates to an apparatus and method for producing highly collimated light and, more particularly, to a method for producing highly collimated light for use with a tiled, flat-panel liquid crystal display (LCD).
BACKGROUND OF THE INVENTION
Conventional flat-panel displays made in accordance with known liquid crystal display technologies have heretofore been both limited in size and expensive to manufacture. A large display device may be constructed at reduced cost by assembling multiple smaller display "tiles". However, it is necessary to make the internal seams visually imperceptible to create a pleasing display.
For the seams to be visually imperceptible and for the display image to be sharp, the light used to illuminate the display must be highly collimated. A collimated light source must allow essentially no visible energy to radiate beyond an allowable off-normal angle. The allowable off-normal angle is prescribed by the tile thickness and the cover plate mask and back plate mask dimensions. It is defined as the critical off-normal angle below which light from the illumination source must not enter the tile to tile seam area. This type of tiled display construction is described in U.S. Pat. No. 5,661,531, entitled "Construction and Sealing of Tiled, Flat-Panel Displays"; and co-pending U.S. patent application, Ser. No. 08/593,759, filed on Jan. 29, 1996, entitled "Tiled, Flat-Panel Display Having Invisible Seams". Both U.S. Pat. No. 5,661,531 and co-pending application Ser. No. 08/593,759 are hereby incorporated by reference.
Typical practice for LCD illumination uses area light sources such as fluorescent tube arrays. A collimator must focus the light from the light source forward, toward the flat-panel display, forcing essentially all visible light energy to fall within the off-normal angle described hereinabove. Most commonly used collimators do reduce the light intensity at large off-normal angles, but do not perform well enough at small off-normal angles for use with a tiled, flat-panel display having visually imperceptible seams. A seamless appearance in a tiled, flat-panel display requires that unwanted visible light energy outside of the off-normal angle be reduced to less than one percent of the intensity of the light at a normal angle. This percentage is derived in a 1992 reference paper by G. Alphonse and J. Lubin entitled "Psychophysical Requirements for a Tiled Large Screen Display" published in SPIE Journal, Volume 1664, pp. 230-240.
In tiled, flat-panel constructions featuring a cover plate with an integral screen, the light must also be collimated to such an extent that essentially no light from one pixel can reach the screen area associated with any other pixel. Adherence to this requirement produces the sharpest possible image on the tiled, flat-panel display.
It is therefore an object of the invention to provide an apparatus and method for producing highly collimated light suitable for use with a tiled, flat-panel display having visually imperceptible seams.
It is a further object of the invention to provide a means of reducing the intensity of visible light energy, which falls outside of a desired, off-normal angle, to an acceptable level.
It is yet another object of this invention to maximize the pixel resolution in tiled, flat-panel displays by providing highly collimated light.
It is a further object of this invention to produce a wide area, collimated light source having a small depth to enable building tiled, flat-panel displays having a small overall thickness.
The present invention provides an apparatus and method for producing the highly collimated light required for use with a seamless, tiled, flat-panel display.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided an apparatus and method for collimating light for use with a tiled, flat-panel display having a seamless appearance (i.e., having visually imperceptible seams). Both U.S. Pat. No. 5,661,531 and co-pending U.S. patent application Ser. No. 08/593,759 describe methods for producing Active Matrix LCD (AMLCD) displays by using multiple tiles coupled together in large, visually seamless arrays. The light from the illumination source for the display must be collimated to meet stringent optical standards to ensure optimum performance of the total display system. Collimation and distribution of light from the light source is typically accomplished by some or all of the following components: diffusers, brightness enhancing films, optical lenses, light-directing screens, collimating sheets, wave guides and opaque masks. The use of these components adds cost, complexity and thickness to the final display system and, in the end, they do not collimate the light sufficiently to produce a seamless appearance in a tiled, flat-panel display.
The present invention provides a novel method for collimation in a tiled, flat-panel display environment. In the inventive method, a lattice of depth, H, having an x,y cell width, W, is placed a distance, D, behind the bottom mask of the tiled, flat-panel display assembly, but in front of the illumination source. The lattice is formed from a thin, non-reflective material so that the acceptable light passing through the lattice is not "blocked" to any significant extent, but the unwanted (off-axis) light impinges upon the lattice cell walls and is absorbed. The lattice is formed from a material with surfaces that have small and uniformly minimal specular and diffuse reflectivity across the visible spectrum of light. The lattice is made with a specific relationship of cell height to cell width, typically between 1:1 and 3:1. Such cell height to cell width ratios generally keep light rays that are beyond acceptable off-normal angles, from entering the display assembly (back plate, tiles, cover plate, etc.). The lattice is placed a distance behind the display, typically between one and three times the lattice thickness, so that the cell walls of the lattice are not "imaged" onto the back of the display assembly. Such a lattice used in this way is a simple, practical way to achieve the highly collimated light required for visually imperceptible seams in a tiled, flat-panel display.
BRIEF DESCRIPTION OF THE DRAWINGS
A complete understanding of the present invention may be obtained by reference to the accompanying drawings, when considered in conjunction with the subsequent detailed description and in which:
FIG. 1 is a sectional, schematic view of a flat-panel display with its associated illumination source;
FIG. 2 is a plan view of three embodiments of collimating lattice geometries;
FIG. 3 is a graph showing the light-collimating ability of each element depicted in FIG. 1;
FIG. 4 is a schematic representation of a pixel and its neighboring pixels in a tiled, flat-panel display; and
FIG. 5 is a sectional, schematic view of a flat-panel display, including an optical collimator.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Generally speaking, the invention features an apparatus and a method for constructing a highly collimated light source for use with a seamless, flat-panel display. The degree of collimation required to achieve a seamless appearing display with a sharp image may be obtained with an open cell lattice having non-reflecting side walls. Both the lattice dimensions and the position of the lattice relative to the display are chosen so as to provide optimum collimation and illumination.
Referring now to FIG. 1, a cross-sectional view of a tiled, flat-panel display assembly, using the inventive collimating lattice, is shown generally at reference numeral 10. Display assembly 10 utilizes a conventional light box 12 in conjunction with the collimating lattice 14 and a tiled, flat-panel display 16. A conventional light source for an LCD display would normally consist of three elements: a light box 12 housing one or more fluorescent lamps 18, a diffuser sheet 20, and an optical collimator (brightness enhancing films) 22. This invention adds a fourth element: a collimating lattice 14, having thickness H, and displaced distance D from the LCD display 16. Lattice 14 is used to produce the highly collimated light needed for use with a tiled, flat-panel display having visually imperceptible seams and a sharp image. Dimensions H and D will be discussed in detail hereinbelow.
Referring now to FIG. 2, there are shown plan views of three geometric shapes of collimating lattices suitable for use in practicing the method of the present invention. The upper portion of FIG. 2 shows a lattice of square cells 30; the middle portion of FIG. 2 shows a lattice having triangular cells 40; and the lower portion of FIG. 2 shows a lattice formed from hexagonal or honey comb cells 50. The lattice cells 30, 40, 50 can be characterized by a typical cell width dimension W, of 3-5 mm, 32, 42, 52, respectively. The lattice 30, 40, 50 may be constructed from any material that is thin, such as plastic, paper, aluminum, or other metals. The interior surfaces of the cells, not shown, may be plated, dyed, painted, or treated in any other way known to those of skill in the art, to produce a surface with uniformly minimal specular and diffuse reflectivity across the visible spectrum of light. Instead of surface treatment, the material itself can be non-reflective. The wall thickness of the cells, not shown, is minimized to permit as much light as possible to pass through the lattice 30, 40, 50. In the preferred embodiment, a readily available aluminum honey comb lattice is spray- or dip-painted with a matte black paint.
Referring now to FIG. 3, there is shown a graph 60 of the relative collimating efficiencies of various collimating elements of the light source shown in FIG. 1: diffuser 20, optical collimator 22 and lattice collimator 14. Referring now again also to FIG. 1, an ideal diffuser 20 should disperse the light from the lamps 18 forward in all directions, at uniform brightness. Light intensity should be constant at all angles measured with respect to a line 24 normal to the front or rear surface planes of the diffuser 20. Light of this nature is referred to as Lambertian. The light from lamps 18 first passes through diffuser 20 and then passes through an optical collimator or brightness enhancing film 22. These readily available devices are usually constructed of micro-geometry prismatic arrays or channels which change the Lambertian-like light distribution from a typical diffuser to a more forward peaked distribution, producing the light intensity versus off-normal angle curves 62 and 64, respectively. The light energy at angles above the desired cut-off angle (i.e., that which remains when only diffuser 20 and optical collimator 22 are used) is too high for use with a tiled, flat-panel display having visually imperceptible seams and a sharp appearance. The addition of collimating lattice 14 in accordance with the invention removes virtually all light beyond the desired cut-off angle as shown in curve 66, thus producing the desired seamless, sharp appearance of the display.
Referring now to FIG. 4, there is shown generally at reference number 100, a schematic view of a target display pixel 102 adjacent to a tile edge 104. Neighboring pixels, 106, 108, 108', 110 and 110' are also shown. Light entering the rear of the display (arrow 112) in the target pixel area 102 at off-normal angles beyond the desired cut-off angle exit the display in a neighboring pixel, for example through pixel areas 108 or 108'. Light passing through the display encounters a succession of optical active media: a polarizer, then liquid crystal material, and then another polarizer. At the juncture or seam 104 of two tiles, light which enters a pixel area adjacent to the seam 104 at large off-normal angles passes through the seam area between the tiles, avoiding the liquid crystal material, and exits the display through a pixel area in the adjacent tile, thereby making the seam 104 visible to the viewer. The collimating lattice 14 of this invention prohibits light that is beyond the desired off-normal angle from entering the display. The resultant effect is that pixel 110 has the same appearance (illumination level) as pixel 110' and pixel 108 has the same appearance as 108' when the target pixel 102 is illuminated.
It is desired to have light which enters the display behind the target pixel 102, pass through only the target pixel's optically active (i.e., liquid crystal) media, and exit to the viewer only in the area defined by the target pixel 102. In practice this rarely happens. Some light from adjacent pixel areas 106, 108, 110, etc. enters the target pixel 102 and exits the display through other adjacent pixel areas 106, 108, 110, etc. In addition, light entering the target pixel area 102 also exits through adjacent pixel areas 106, 108, 108', 110'. This bleeding effect limits the actual resolution of the display. The viewer is not able to discriminate individual pixels if too much stray light (light beyond the desired cut-off angle) illuminates the rear of the display. An image viewed on a display with too much stray light is perceived as out of focus compared to the same image viewed on a display with less stray light. In other words, an image viewed on a display without excessive stray light is perceived as sharper than an image viewed on a display with excessive stray light.
Referring now to FIG. 5, an alternative apparatus and method for producing light for a LCD display are shown, generally at reference numeral 120. This method is based on edge lighting a wave guide 122 with small diameter fluorescent lamps 18. Waveguide 122 is made of an optically clear material such as acrylic, glass, or polycarbonate. A collimating sheet 124 is bonded to the top of wave guide 122 using an optically transmissive adhesive having a suitable index of refraction such as acrylic adhesive or clear silicone adhesive. Collimating sheet 124 typically comprises arrays of Fresnel-type lenses and works on the principle of total internal reflection. The light produced by such a light source assembly 18, 122, 124 is collimated, but not sufficiently for a tiled, flat-panel display 16 to appear sharp and seamless. The addition of a collimating lattice 14 used in conjunction with this type of light source assembly does provide the necessary degree of collimation.
The desired collimation angle can be calculated from a consideration of the display pixel geometry and mask geometry within display 16. The collimating lattice 14 is selected by choosing a ratio of lattice cell width W 32, 42 or 52 to lattice cell depth H 130, equal to the tangent of the desired collimation or cut-off angle. The collimating lattice 14 must be placed a sufficient distance, D 132, behind the display so that the shadow of the cell geometry itself is not imaged (i.e., projected or shadowed) onto display 16.
A typical tiled display 16 may dictate a collimation angle of 25 degrees off-normal. The lattice is then selected with a height H 130 equal to twice the cell width W. A larger ratio may also work, but can result in discarding more of the available visible light energy than is necessary. The collimating lattice 14 must be placed at a distance of at least D 132 from the display 16 greater than twice the cell height H 130 in order to avoid imaging the lattice 14 by the display 16 in this example. Typically, the ratio of the lattice cell width W to cell height H 130 is the same as the ratio of the cell height H 130 to lattice-to-display distance D 132. There is no required relationship between the pixel pitch or spacing, not shown, in display 16 and the collimating lattice 14 cell dimensions.
Since other modifications and changes varied to fit a particular operating requirements and environment will be apparent to those skilled in the art, the invention is not considered limited to the example chosen for purposes of disclosure, and covers all changes and modifications which do not constitute a departure from the true spirit and scope of the invention. Having thus described the invention, what is desired to be protected by Letters Patent is presented in the subsequent appended claims. | The present invention features an apparatus and method for collimating light for use with a tiled, flat-panel display having a seamless appearance (i.e., having visually imperceptible seams). A novel, multi-cell, collimation lattice is placed behind the bottom mask of the tiled, flat-panel display assembly, but in front of an illumination source. The lattice is formed from a thin, non-reflective material, so that the acceptable light passing through the lattice is not "blocked", but the unwanted (off-axis) light impinges upon the lattice cell walls and is absorbed. | 16,567 |
BACKGROUND OF INVENTION
[0001] Oil-based sludges of various types and consistencies are commonly generated as waste streams during oil or other hydrocarbon production processes. These sludges arise during well tests and initial production, as a by-product waste stream of hydrocarbon production, and as tank bottom sediments. The basic components of sludges are hydrocarbon oils of various consistencies, water, and solids of an inorganic and organic nature. Oil-based sludge typically refers to a complex water-in-oil emulsion stabilized by salts of organic compounds and fine solids. The oil phase contains a complex mixture of hydrocarbons of various consistencies including waxes and asphaltenes which may be solid or semi-solid at ambient temperature.
[0002] The chemistries of oil-based sludges and the relative proportions of the oil, water, and solid phases of sludges vary greatly and can change over time. To dispose of the waste, sludge is often stored in open pits where it may be left for considerable time before being treated. During such aging periods, the sludge or “pit sludge” undergoes overall chemical composition changes due to the effects of weathering, including: volatilization of lighter hydrocarbons; temperature induced crosslinking of hydrocarbons; addition of rain water; and, invariably, the introduction of a variety of other contaminants, particulates, and debris. In addition to a variable complex chemistry, oil-based sludge typically has a high solids content. Sludge solids normally include both high density and low density solids. High density solids, i.e., high gravity solids, may be large solids introduced into the drilling fluid during the drilling of a formation (e.g. formation solids, drill bits, etc.) or other solids that are relatively dense such as barite or hermatite. While low density solids, i.e., low gravity solids, are those solids within the sludge that have a lower density or are relatively small fine solids (e.g., entrained solids such as sand).
[0003] Currently, treatment of sludge is a major operational cost for producers. Sludge is collected, stored, and then disposed of in tanks or delivered to a sludge pit. One challenge of sludge treating systems is that the recovery of marketable oil from the sludge is generally not cost-effective and thus not commercially viable. Due to wide variability in sludge composition, different sludge processing systems may be needed to optimize the processing of sludge for recovering oil of sufficient quality in a cost efficient manner. The quality of oil is frequently characterized by its Basic Sediment and Water (BS&W) content, in vol. %. The current marketable BS&W of recovered oil is less than about 2 vol. %. Furthermore, it is desirable to treat pit sludge to reduce the risk of contamination of the surrounding pit area, in accordance with increasingly strict environmental regulations, as well as decrease the overall waste volume, and ultimately to permit pit closure.
SUMMARY
[0004] The present invention is generally directed to a modular oil-based sludge separation and treatment apparatus that is easily adapted to provide processing flexibility in order to ensure quality oil recovery from oil-based sludge in an efficient and cost-effective manner. The modular approach allows the configuration of processing equipment to be adapted to the oil-recovery processing requirements of the particular oil-based sludge composition. Providing a customizable apparatus maximizes the quantity and quality of the recovered oil while minimizing the processing time and cost to the operator.
[0005] It is an objective of the present invention to provide a modular apparatus having certain processing equipment mounted on portable skids that are adaptable and versatile to permit customized arrangement for oil-recovery processing of a wide range of oil-base sludge compositions in a cost-efficient manner.
[0006] In one aspect, the invention is directed to a modular apparatus for recovering oil from oil-based sludge having a high concentration of low density solids. The modular apparatus includes: a pumping skid having a pump operable to homogenize an oil-based sludge; a shaker skid having a screen that removes particulates from the oil-based sludge as the sludge traverses the screen to form a debris-free sludge; a heating skid shaving a heat exchanger operable to heat the debris-free sludge as: the debris-free sludge flows through the heat exchanger to form a heated sludge; a chemical skid having at least one chemical injection mixer operable to inject a chemical into the heated sludge and mix the chemical with the heated sludge to form a chemically-treated sludge; a phase separator skid having a three-phase separator operable to separate the phases of the chemically-treated sludge to form a first solids component stream, a first water component stream, a first oil component stream, and a first gas component stream; a decanter skid having a decanter centrifuge operable to remove solids from the first oil component stream to form a second solids component stream and a second oil component stream; and an oil purification skid having a disk stack centrifuge operable to remove water and solids from the second oil component stream to form a third solids component stream, a second water component stream, and a third oil component stream.
[0007] In another aspect, the invention is directed to a modular apparatus for recovering oil from oil-based sludge having a high concentration of high density solids. The modular apparatus includes: a pumping skid: having a pump operable to homogenize an oil-based sludge; a shaker skid having a screen that removes particulates from the oil-based sludge as the sludge traverses the screen to form a debris-free sludge, a heating skid having a heat exchanger operable to heat the debris-free sludge as the debris-free sludge flows through the heat exchanger to form a heated sludge; a first chemical skid having at least one chemical injection mixer operable to inject a chemical into the heated sludge and mix the chemical with the heated sludge to form a first chemically-treated sludge: a decanter skid having a decanter centrifuge operable to remove solids from the first chemically-treated sludge to form a first solids component stream and a decanter-processed sludge; a second chemical skid having at least one chemical injection mixer operable to inject a chemical into the decanter-processed sludge and mix the chemical with the decanter-processed sludge to form a second chemically-treated sludge; a phase separator skid having a three-phase separator operable to separate the phases of the second chemically-treated sludge to form a second solids component stream, a first water component stream, a first oil component stream, and a first gas component stream; and an oil purification skid having a disk stack centrifuge operable to remove water and solids from the first oil component stream to form a third solids component stream, a second water component stream, and a second oil component stream.
[0008] In still another aspect, the invention is directed to a modular apparatus for recovering oil from oil-based sludge having very low solids content. The modular apparatus includes: a pumping skid having a pump operable to homogenize an oil-based sludge; a shaker skid having a screen that removes particulates from the oil-based sludge as the sludge traverses the screen to form a debris-free sludge; a heating skid having a heat exchanger operable to heat the debris-free sludge as the debris-fee sludge flows through the heat exchanger to form a heated sludge; a chemical skid having at least one chemical injection mixer operable to inject a chemical into the heated sludge and mix the chemical with the heated sludge to form a chemically-treated sludge; a phase separator skid having a three-phase separator operable to separate the phases of the chemically-treated sludge to form a first solids component stream, a first water component stream, a first oil component stream, and a first gas component stream; and an oil purification skid having a disk stack centrifuge operable to remove water and solids from the first oil component stream to form a second solids component stream, a second water component stream, and a second oil component stream.
[0009] These and other features are more fully set forth in the following description of preferred or illustrative embodiments of the disclosed and claimed subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
[0011] FIG. 1 is a flow chart depicting a modular skid arrangement optimized for recovering the valuable hydrocarbon component of pit sludge having a high concentration of low density solids, according to an embodiment of the invention;
[0012] FIG. 2 is a flow chart depicting another modular skid arrangement optimized for recovering the valuable hydrocarbon component of pit sludge having a high concentration of high density solids, according to another embodiment of the invention;
[0013] FIG. 3 is a flow chart depicting still another modular skid arrangement optimized for recovering the valuable hydrocarbon component of pit sludge having very low solids content, according to still another embodiment of the invention;
[0014] FIGS. 4 and 5 are schematics of an exemplary modular apparatus for separating and treating an oil-base sludge having a high concentration of low density solids to recover the valuable hydrocarbon component, in accordance with the skid arrangement shown in FIG. 1 ;
[0015] FIGS. 4 and 6 are schematics of an exemplary modular apparatus for separating and treating an oil-base sludge having a high concentration of high density solids to recover the valuable hydrocarbon component, in accordance with the skid arrangement shown in FIG. 2 ; and
[0016] FIGS. 4 and 7 are schematics of an exemplary modular apparatus for separating and treating an oil-base sludge having very low solids content to recover the valuable hydrocarbon component, in accordance with the skid arrangement shown in FIG. 3 .
DETAILED DESCRIPTION
[0017] The claimed subject matter relates to a modular apparatus having one of several skid arrangements depicted in FIGS. 1-3 for recovering the valuable hydrocarbon component of oil-based sludges having a wide variability in sludge composition. Depending upon the particular sludge composition and its solids content, the skid arrangements of the modular apparatus of the present invention may be easily configured, and re-configured, in order to optimize the separation and purification of the recovered oil while minimizing the time and cost to an operator.
[0018] According to an embodiment of the invention, FIG. 1 depicts the skid arrangement: of a modular apparatus 100 optimally configured for recovering the valuable hydrocarbon component of sludge 14 initially having a high concentration of low density solids, Modular apparatus 100 comprises a pumping skid 102 , a shaker skid 104 , a heating skid 106 , a chemical skid 108 , a phase separator skid 110 , a gas purification skid 112 , a decanter skid 114 , and an oil purification skid 116 . Each of the skids 102 - 116 are described in more detail in the description that follows with respect to the modular apparatus 100 schematically illustrated in FIGS. 4 and 5 .
[0019] As illustrated in FIGS. 4 and 5S modular apparatus 100 processes pit sludge through the pumping skid 102 , the shaker skid 104 , the heating skid 106 , the chemical skid 108 , the phase separator skid 110 , the gas purification skid 112 the decanter skid 114 , and the oil purification skid 116 . Referring to FIG. 4 , the pumping skid 102 includes a hydraulic submersible sludge pump 122 that homogenizes a pit sludge 10 contained in a pit 12 and then pumps a homogenized sludge 14 to the shaker skid 104 . The pump 122 may be mounted on a hydraulic arm in order to reach inner areas of the pit 12 . During ageing, the pit sludge 10 separates into basically three layers or phases, wherein the top layer of the pit is an oil-rich phase, the middle layer of the pit sludge 10 is a water-rich phase, and the bottom layer of the pit sludge 10 is a solids-rich phase. The pump 122 forms a homogeneous mixture or slurry of the three phases contained within the pit in order to provide a generally constant feed composition to the remainder of the apparatus 100 for processing.
[0020] The shaker skid 104 includes a shaker screen 124 and a holding tank 126 mounted thereon and within the confines of the area in the skid 104 so as to maintain portability of the skid 104 . The shaker screen 124 physically separates and removes large particulates such as stones or debris from the sludge 14 . A debris-free sludge 16 exiting the shaker screen 124 collects in the holding tank 126 . Holding tank 126 may be essentially any type of tank that can contain a sufficient amount of sludge to supply and maintain a constant sludge flow rate to a heat exchanger 130 . A first transfer pump 128 in fluid communication with the holding tank 126 transfers the sludge 16 from the holding tank 126 to the heating skid 106 . In a preferred embodiment, the holding tank 126 is an augured V-Tank coupled to the pump 128 which is VFD (variable frequency driver) controlled in order to automatically provide a steady state flow rate of the sludge 16 to the heat exchanger 130 .
[0021] The heating skid 106 has the heat exchanger 130 , a steam boiler 132 , and a fuel tank 134 mounted thereon and within the confines of the area of the skid 106 so as to maintain the portability of the skid 106 . Sludge 16 is heated to a desired temperature as it travels through the heat exchanger 130 . Because oil-based sludges often include waxy hydrocarbons, heating advantageously melts the waxy hydrocarbons into liquid form and lowers the viscosity of the sludge 16 . Also, heating advantageously aids in breaking the emulsion (secondary phase) and promotes phase separation within the sludge 16 . Providing heat to the heat exchanger 130 is accomplished by use of the steam boiler 132 . The steam boiler 132 generates steam and circulates the steam to the heat exchanger 130 via a first steam line 136 and a second steam line 138 . The flow rate, pressure, and temperature of the steam entering the heat exchanger 130 via line 136 are controlled so as to provide adequate heat transfer to the sludge 16 as it flows through the heat exchanger 130 . A heated sludge 18 , having the desired temperature and viscosity, exits the heat exchanger 130 and is subsequently transferred to the chemical skid 108 . In one example, the type of heat exchanger 130 used is a spiral type heat exchanger, wherein sludge 16 flows through the heat exchanger 130 in a path separate from that of the steam, but adjacent to it such that heat from the steam is transferred to the sludge 16 . It is understood that other types of heat exchangers can be used without departing from the scope of this invention.
[0022] Depending upon the particular sludge composition, the sludge 16 is heated to essentially any temperature sufficient to liquefy the sludge 16 and lower its viscosity. When the viscosity is lower, treatment chemicals may be more easily blended with the heated sludge 18 in downstream processing. Furthermore, when the sludge viscosity is lower, entrained solids are more easily released in downstream processing. The desired temperature of the heated sludge 18 and its corresponding rheological profile can be predetermined and optimized using a viscometer, such as an oilfield Fann 35 viscometer available from Fann Instrument Co. In one example, sludge 18 is heated to a temperature in the range from about 65° C. to about 85° C. to sufficiently liquefy the sludge 18 and reduce its viscosity for downstream processing. More preferably, sludge 18 is heated to a temperature in the range from about 70° C. to about 80° C. Although it is desirable to heat the sludge 16 , care should be taken to ensure that the temperature of the heated sludge 18 is lower than the flash point temperature of the sludge 16 . The flash point is that minimum temperature at which there is enough evaporated fuel in the air to start combustion. The flash point of the sludge 16 can be determined by the use of a flash-point measuring device such as the Pensky Martens Closed Cup according to method ASTM D93B.
[0023] Preferably, the fuel tank 134 is co-located on the skid 106 to provide fuel to the steam boiler 132 for heating the steam. Optionally, a power supply (not shown) is provided on the skid 106 to actuate valves (not shown) that regulate the flow rate of the steam through the first and second steam lines 136 , 138 , and also regulate the flow rates of the water supply and the fuel provided to the steam boiler 132 . A control panel (not shown) may be co-located on the skid 106 to monitor and automatically control the valves in order to automate the heating process at the heat exchanger 130 . In addition, the boiler 132 , flow lines 136 , 138 , and heat exchanger 130 are preferably thermally insulated to better maintain temperature uniformity and control.
[0024] Once heated, the sludge 18 is transferred to a chemical skid 108 for chemically altering the sludge 18 to break up the emulsion and promote phase separation. The chemical skid 108 includes a plurality of chemical injection mixers 140 a - d and chemical supply tanks 142 a - d mounted thereon and within the confines of the area of the skid 108 so as to maintain the portability of the skid 108 . Chemical addition is typically required to destabilize the emulsion and change such properties to enhance separation of the water and solids from the sludge 18 , as well as decrease the separation: time required. Each of the chemical injection mixers 140 a - d includes a static shear mixer having an injection point. The injection point introduces a chemical into the sludge 18 while the mixer simultaneously blends the chemical and the sludge 18 under the shearing action of the mixer. The chemical injection mixer advantageously provides a homogeneous distribution of the chemical within the sludge 18 to aid in its complete and efficient chemical reaction therein. As depicted in FIG. 5 , four chemicals are added to the heated sludge 18 as the sludge is directed through the chemical injection mixers 140 a - d . Each of the chemical injection mixers 140 a - d has a corresponding chemical supply tank 142 a - d for storing the chemicals until they are transferred via chemical lines 144 a - d to the mixers 140 a - d for injection into the sludge 18 . Once all the chemicals are introduced and blended into the heated sludge 18 , a chemically-treated sludge 20 exits the last chemical injection mixer 140 d and is subsequently transferred to the phase separator skid 110 for further processing.
[0025] Depending upon the particular initial sludge 14 composition, a wide variety of chemicals, may be introduced and blended into the sludge 18 in order facilitate subsequent processing to separate the solid, water, and oil phases of the chemically treated sludge 20 . Suitable chemicals include acids, demulsifiers, wetting agents, surfactants, flocculants, and defoamers. Demulsifiers modify the interfacial tension of the emulsion film to release the water and assist in separating out the water from the oil. Wetting agents alter the wetability of solid particles thereby causing the solid particles to become hydrophilic which increases the solids affinity for water and causes further breakup of the interfacial emulsion film. Flocculants induce the solids to aggregate and form larger solids to facilitate separation of the solids in the sludge. In one example, as the heated sludge 18 travels through the first injection mixer 140 a , the mixer 140 a injects an acid and blends the acid with the sludge 18 therein in order to neutralize adsorbed ions present at the interfacial emulsion film of the sludge 18 and chemically prepare the sludge 18 for chemical treatment with a demulsifier. Subsequently, the sludge 18 is directed through the second injection mixer 140 b wherein a demulsifier is injected and blended into the sludge 18 to break the interfacial emulsion film for release of the secondary water phase. The sludge 18 then passes through the third injection mixer 140 c wherein a wetting agent is injected and blended into the sludge to alter the affinity of the solids towards the water phase. Afterwards, the sludge 18 passes through the fourth injection mixer 140 d wherein a defoamer is injected and blended into the sludge for the purpose of counteracting surfactants (detergents) present in the sludge that may otherwise undesirably cause foaming. After chemical treatment in injection mixers 140 a - d , a chemically-treated sludge 20 exits the chemical skid 108 and is ready for subsequent processing. It should be noted that the present invention is not intended to be limited to the use of any particular chemicals, and other chemicals may be substituted for any of the aforementioned chemicals.
[0026] Furthermore, additional chemicals may be incorporated into the sludge 18 by providing additional injection mixers (e.g., 140 e - n ) on the skid 108 such that all the desired chemicals may be introduced into the sludge. For example, a fifth injection mixer (not shown) may be included on skid 108 to introduce a pour point suppressant into the sludge 18 in order to extend the fluidity of the sludge to lower temperatures. Because wax in the sludge can cause issues for pumping and phase separation in terms of the high viscosity it imparts and coating of entrained solids, pour point suppressants can be added to depress the temperature at which wax molecules in the oil phase of the sludge 18 solidify, Conversely, in another example, fewer chemicals may be incorporated into the sludge 18 by bypassing one or more of the injection mixers 140 a - d or, alternatively, removing one of more of the mixers 140 a - d from the skid 108 .
[0027] Preferably at least one dosing pump (not shown) in fluid communication with each of the chemical injection mixers 140 a - d is used to provide a predetermined quantity of chemical to the injection point of the mixer for introduction into the sludge 18 . The quantity of each of the chemicals introduced into the sludge 18 depends upon the particular initial sludge composition 14 . For example, a dosing pump in fluid communication with the second injection mixer 140 b provides demulsifier in the predetermined amount of 2-3% by volume of sludge 18 . Although essentially any type of dosing pump may be used, in one example each of the dosing pumps is a gear pump with a VFD control panel. In addition, preferably, the chemical injection mixers 140 a - d are thermally insulated to better maintain the sludge temperature and fluidity.
[0028] After chemical treatment, the sludge 20 is directed to the phase separator skid 110 for separating the solid, water, oil, and gas phases of the sludge 20 . The phase separator skid 110 includes a surge tank 146 and a three-phase separator 148 mounted thereon and within the confines of the area of the skid 110 so as to maintain the portability of the skid 110 . The sludge 20 is fed into the vertically-oriented surge tank 146 which separates heavier solids from the sludge 20 and provides a continuous flow of a liquid portion of the sludge 22 to the three-phase separator 148 . The surge tank 146 contains an interior plate that facilitates the small solids (e.g., solids in suspension) within the sludge 20 to aggregate and form larger solids such that gravity is sufficient to separate these heavier solids out of the sludge 20 . Separated solids 24 that settle and accumulate in a bottom region of the surge tank 146 are discharged and directed to a solids receiving tank 150 . The liquid portion of the sludge 22 , which comprises oil, water, gas, and fine solids, is directed to the three-phase separator 148 .
[0029] The liquid portion of the sludge 22 flows into the three-phase separator 148 through an inlet located at one end of the separator 148 . The separator 148 is designed to separate the phases and flow the separated phases to their respective outlets. Within the retention section of the three-phase separator 148 , the liquid portion of the sludge 22 separates into a water-rich phase 28 , an oil-rich phase 30 , and a gas phase 44 . Furthermore, additional solids 26 that may settle out of the sludge 22 and accumulate in a bottom region of the separator 148 , primarily as a result of the re-distribution or separation of the phases, are discharged and directed to the solids receiving tank 150 . The water-rich phase 28 is discharged to a water tank 152 . The oil-rich phase 30 is transferred to the decanter skid 114 for fine solids removal. The gas phase 44 is directed to the gas purification skid 112 to clean the gas for release into the atmosphere. One exemplary three-phase separator 148 is the Horizontal Longitudinal Flow Separator commercially available from NATCO Group Inc., Houston, Tex. However, the present invention is not limited to a particular type of surge tank or three-phase separator. In addition, the surge tank 146 and three-phase separator 148 are both preferably insulated to better maintain the sludge temperature and fluidity.
[0030] The oil-rich phase 30 is transferred to the decanter skid 114 to separate the fine solids out of the oil-rich phase 30 . The decanter skid 114 includes a decanter centrifuge 154 and a heating tank 156 mounted thereon and within the confines of the area of the skid 114 so as to maintain the portability of the skid 114 . For the removal of solids, the decanter centrifuge 154 is particularly useful in reducing the solids content in liquids having a solids concentration in excess of about 3 vol. % to a solids concentration less than about 2 vol. %. Once the oil-rich phase 30 is fed into the decanter centrifuge 154 , centrifugal force causes suspended solids to separate out of the oil-rich phase 30 and coalesce for subsequent removal from the decanter, Solids 32 are discharged through a solids outlet located in the bottom of the decanter centrifuge 154 . At this point in the processing, a decanter-processed oil-rich phase 34 that exits the decanter 154 has a BS&W of less than about 2 vol. %. Suitable decanter centrifuges include decanter centrifuges having a rotational speed of 3000 rpm or greater. Exemplary decanter centrifuges include Model 500 (3000 rpm) and Model 518 (5000 rpm) commercially available from M-I L.L.C., Houston, Tex.
[0031] After the fine solids removal, the decanter-processed oil-rich phase 34 is transferred to the heating tank 156 and optionally heated therein. Because a significant amount of cooling can occur during the various prior processing steps, since being previously heated in the heat exchanger 130 , the oil-rich phase 34 is optionally heated to a desired temperature in the heating tank 156 in order to enhance its final phase separation and purification during the next processing step at the oil purification skid 116 . The heating tank 156 includes a heating element (e.g., a steam coil) capable of heating the contents of the tank 156 . After heating, a heated oil-rich phase 36 is pumped via a second transfer pump 158 to the oil purification skid 116 for final purification. In one example, the heated oil-rich phase 36 is heated to a temperature in the range from about 65° C. to about 85° C.
[0032] The heated oil-rich phase 36 is transferred to the oil purification skid 116 for its final purification and recovery of oil therefrom having a BS&W of less than about 1 vol. %. The oil purification skid 116 includes a disk stack centrifuge 160 . As depicted in FIG. 5 , the heated oil-rich phase 36 is fed into the disk stack centrifuge 160 to further purify the oil. The disk stack centrifuge uses a combination of plates (i.e., the disk stack) and extremely high centrifugal forces to separate the very fine water emulsion and the ultra-fine solids out of the oil-rich phase 36 . After separation, a water stream 38 , a recovered oil stream 40 , and an ultra-fine solids phase 42 are discharged from the centrifuge 160 . After final processing in the disk stack centrifuge 160 , the recovered oil stream 40 has a BS&W less than about 1 vol. % and is commercially marketable. Exemplary disk stack centrifuges are commercially available from Alfa Lavel Inc., Richmond, Va.
[0033] The gas phase 44 is transferred to the gas purification skid 112 where the gas phase 44 is treated to remove volatile organic compounds (VOCs) prior to discharge into the environment. The gas purification skid 112 preferably includes a free water knockout pot 162 , at least one mist impinger 166 , and at least one activated carbon filter 168 mounted thereon and within the confines of the area of the skid 112 so as to maintain the portability of the skid 112 . A VFD-controlled vacuum blower 164 attached to the knockout pot 162 is used to draw the gas phase 44 from a gas vent located in an upper side of the three-phase separator 148 through the knockout pot 162 filled with water. The gas phase 44 enters a gas inlet located near the bottom of the knockout pot 162 , and hydrocarbons in the gas phase 44 adhere to the water as the gas travels upwardly through the pot 162 . Water in the knockout pot 162 is periodically emptied into a liquid waste disposal and replaced with fresh water. Because the exiting gas is saturated with water, a wet-gas 46 that exits a gas outlet near the top of the knockout pot 162 is directed through at least one mist impinger 166 to remove water from the gas 46 and provide a dry gas 48 . The dry gas 48 that exits the at least one mist impinger 166 is then transferred to an activated carbon filter 168 to remove contaminants (e.g., remaining VOCs) therefrom in order to ensure a gas 50 that meets the environmental regulatory standards for release to the atmosphere. In one example, as depicted in FIG. 5 , the knockout pot 162 removes hydrocarbons from the gas phase 44 , and afterwards the exiting wet-gas 46 is directed through two mist impingers 166 to adequately dry the gas prior to directing the dry gas 48 through one or more activated carbon filters 168 . When the activated carbon filter 168 becomes exhausted, it may be treated to reactivate the carbon or, alternatively, may be disposed of according to appropriate regulatory procedures.
[0034] According to another embodiment of the invention, FIG. 2 depicts the skid arrangement of a modular apparatus 200 optimally configured for recovering the valuable hydrocarbon component of sludge 14 initially having a high concentration of high density solids. In FIG. 2 the same reference numerals are used to indicate the same skids as those previously described with respect to the apparatus 100 depicted in FIG. 1 . Modular apparatus 200 comprises the pumping skid 1025 the shaker skid 104 , the heating skid 106 , a first chemical skid 118 , the decanter skid 114 , a second chemical skid 120 , the phase separator skid 110 , the gas purification skid 112 , and the oil purification skid 116 . In this embodiment, two chemical skids 118 , 120 are utilized with the decanter skid 114 positioned between the chemical skids 118 , 120 . For sludge 14 initially having a high concentration of high density solids, it is preferable to remove solids from the sludge using a decanter centrifuge prior to delivery of all the chemicals during the chemical treatment of the sludge. Skids 118 and 120 are described in more detail in the description that follows with respect to the modular apparatus 200 schematically illustrated in FIGS. 4 and 6 .
[0035] Illustrated in FIGS. 4 and 6 , modular apparatus 200 processes pit sludge through the pumping skid 102 , the shaker skid 104 , the heating skid 106 , the first chemical skid 118 , the decanter skid 114 , the second chemical skid 120 , the phase separator skid 110 , the gas purification skid 112 , and the oil purification skid 116 . As previously described with respect to FIG. 4 the modular apparatus 200 processes pit sludge 10 through the pumping skid 102 , the shaker skid 104 , and the heating skid 106 to provide a heated sludge 18 .
[0036] Referring now to FIG. 6 , the heated sludge 18 is transferred to the first chemical skid 118 for chemically altering the sludge 18 to break up the emulsion and promote solids separation. In FIG. 6 the same reference numerals are used to indicate the same features as those previously described with respect to apparatus 100 depicted in FIG. 5 . The chemical skid 118 includes a plurality of chemical injection mixers 140 a , 140 b and chemical supply tanks 142 a , 142 b mounted thereon and within the confines of the area of the skid 118 so as to maintain the portability of the skid 118 . Chemical addition is typically required to destabilize the emulsion and change such properties to facilitate separation of the solids from the sludge 18 and decrease the separation time required. Each of the chemical injection mixers 140 a , 140 b includes a static shear mixer having an injection point for introducing a chemical into the sludge 18 while the mixer simultaneously blends the chemical and the sludge 18 under the shearing action of the mixer. As illustrated in FIG. 6 , two chemicals are added to the heated sludge 18 as the sludge is directed through the chemical injection mixers 140 a , 140 b . Chemical supply tanks 142 a , 142 b store the chemicals until they are transferred via chemical lines 144 a , 144 b to the mixers 140 a , 140 b for injection into the sludge 18 . Preferably at least one dosing pump (not shown) in fluid communication with each of the chemical injection mixers 140 a , 140 b is used to provide a predetermined quantity of chemical to the injection point of the mixer for introduction into the sludge 18 . In addition the chemical injection mixers 140 a , 140 b are preferably insulated to better maintain the sludge temperature and fluidity. Once the chemicals are introduced and blended into the heated sludge 18 , a first chemically-treated sludge 202 exits the last chemical injection mixer 140 b and is subsequently transferred to the decanter skid 114 to separate the high density solids out of the first chemically-treated sludge 202 . It should be noted that additional chemical injection mixers may be added to the first chemical skid 118 for the introduction of additional chemicals into the sludge 18 .
[0037] Depending upon the particular initial sludge 14 composition, a wide variety of chemicals may be introduced and blended into the sludge 18 in order facilitate subsequent processing to separate the solids out of the first chemically-treated sludge 202 . Suitable chemicals include acids, demulsifiers, wetting agents, surfactants, flocculants, and defoamers. In one example, as the heated sludge 18 travels through the first injection mixer 140 a , the mixer 140 a injects an acid and blends the acid with the sludge 18 therein in order to neutralize adsorbed ions present at the interfacial emulsion film of the sludge 18 . Subsequently, the sludge 18 is directed through the second injection mixer 140 b wherein a wetting agent is injected and blended into the sludge to alter the affinity of the solids towards the water phase. It should be noted that the present invention is not intended to be limited to the use of any particular chemicals, and other chemicals may be substituted for any of the aforementioned chemicals.
[0038] The first chemically-treated sludge 202 is directed to the decanter skid 114 for solids removal. The chemically-treated sludge 202 entering the decanter skid 114 can have a solids content as high as in the range of 6 vol. % to 15 vol. %. As previously described, the decanter skid 114 includes a decanter centrifuge 154 and a heating tank 156 mounted thereon and within the confines of the area of the skid 114 . The decanter centrifuge 154 is used to reduce the solids content in the sludge 202 to a solids concentration less than about 2 vol. %. In the decanter centrifuge 154 , centrifugal force causes solids 204 to separate out of the sludge 202 and coalesce for subsequent removal from the decanter through a solids outlet located in the bottom of the decanter centrifuge 154 . A decanter-processed sludge 206 that exits the decanter centrifuge 154 has a solids content of less than about 2 vol. %. As previously described, suitable decanter centrifuges include decanter centrifuges having a rotational speed of 3000 rpm or greater.
[0039] After reducing the solids in the sludge 206 , the decanter-processed sludge 206 is transferred to the heating tank 156 and optionally heated therein. Because a significant amount of cooling can occur during the previous processing steps since being heated in the heat exchanger 1301 the decanter processed sludge 206 may be heated to a desired temperature in the heating tank 156 in order to lower its viscosity and facilitate blending of additional chemicals into the sludge 206 during the next processing step at the second chemical skid 120 . After heating, a heated decanter-processed sludge 208 is pumped via the second transfer pump 158 to the second chemical skid 120 . In one example, the heated decanter-processed sludge 208 is heated to a temperature in the range from about 65° C. to about 85° C.
[0040] The heated decanter-processed sludge 208 is transferred to the second chemical skid 120 for chemically altering the sludge 208 to further break up the emulsion and promote phase separation. The chemical skid 120 includes a plurality of chemical injection mixers 140 c , 140 d and chemical supply tanks 142 c , 142 d mounted thereon and within the confines of the area of the skid 120 so as to maintain the portability of the skid 120 , Chemical addition is typically required to further destabilize the emulsion and change such properties to enhance oil-water-solids phase separation during the next processing steps at the phase separator skid 110 . Each of the chemical injection mixers 140 c , 140 d includes a static shear mixer having an injection point for introducing a chemical into the sludge 208 . As illustrated in FIG. 6 , two chemicals are added to the sludge 208 as the sludge travels through mixers 140 c , 140 d . Chemical supply tanks 142 c , 142 d store the chemicals until they are transferred via chemical lines 144 c , 144 d to the mixers 140 c , 140 d . Preferably at least one dosing pump (not shown) in fluid communication with each of the chemical injection mixers 140 c , 140 d is used to provide a predetermined quantity of chemical to the injection point of the mixer for introduction into the sludge 208 . In addition, the chemical injection mixers 140 c , 140 d are preferably insulated to better maintain the sludge temperature and fluidity. Once the chemicals are introduced and blended into the sludge 208 , a second chemically-treated sludge 210 exits the last chemical injection mixer 140 d and is subsequently transferred to the phase separator skid 110 . It should be noted that additional chemical injection mixers may be added to the second chemical skid 120 for the introduction of additional chemicals into the sludge 208 .
[0041] Depending upon the particular sludge 208 composition, a wide variety of chemicals may be introduced and blended into the sludge to promote separation of the water, oil, and solid phases of the second chemically-treated sludge 210 . Suitable chemicals include acids, demulsifiers, wetting agents, surfactants, flocculants, and defoamers. In one example, as the sludge 208 travels through the third injection mixer 140 c , the mixer 140 c injects a demulsifier into the sludge 208 to break the interfacial emulsion film to release the secondary water phase. Afterwards, the sludge 208 is directed through the fourth injection mixer 140 d wherein a defoamer is injected and blended into the sludge for the purpose of preventing foaming. Again, it should be noted that the present invention is not intended to be limited to the use of any particular chemicals, and other chemicals may be substituted for any of the aforementioned chemicals. Furthermore, additional chemical injection mixers may be added to the second chemical skid 120 for the introduction of additional chemicals into the sludge 208 .
[0042] After the second chemical treatment, the sludge 210 is directed to the phase separator skid 11 for separating water and solids from the oil phase of the sludge 210 . As previously described, the phase separator skid 110 includes a surge tank 146 and a three-phase separator 148 mounted thereon. The sludge 210 is fed into the vertically-oriented surge tank 146 which separates solids from the sludge 210 and provides a continuous flow of a liquid portion of the sludge 212 to the three-phase separator 148 . Separated solids 214 that settle and accumulate in a bottom region of the surge tank 146 are discharged to the solids receiving tank 150 . The liquid portion of the sludge 212 which comprises oil, water, gas, and fine solids is directed to the three-phase separator 148 .
[0043] The liquid portion of the sludge 212 flows into the three-phase separator 148 through an inlet located at one end of the separator 148 . After phase separation within the retention section of the three-phase separator 148 , a water-rich phase 218 is discharged to a water tank 152 , an oil-rich phase 220 is transferred to the oil purification skid 116 , and a gas phase 228 is directed to the gas purification skid 112 . Any solids 216 that may settle out of the sludge 212 and accumulate in a bottom region of the separator 148 during separation of the phases are discharged to the solids receiving tank 150 .
[0044] The oil-rich phase 220 is transferred to the oil purification skid 116 for final purification and recovery of oil therefrom having a BS&W of less than about 1 vol. %. As previously described, the oil purification skid 116 includes a disk stack centrifuge 160 mounted thereon. The oil-rich phase 220 is fed into the disk stack centrifuge 160 wherein extremely high centrifugal forces separate the very fine water emulsion and the ultra-fine solids out of the oil-rich phase 220 . After phase separation, a water stream 222 , a recovered oil stream 224 , and an ultra-fine solids phase 226 are discharged from the centrifuge 160 . The recovered oil stream 224 has a BS&W less than about 1 vol. % and is commercially marketable.
[0045] The gas phase 228 is transferred to the gas purification skid 112 where the gas phase 228 is treated to remove VOCs prior to discharge into the environment. As previously described, the gas purification skid 112 preferably includes a free water knockout pot 162 , at least one mist impinger 166 , and at least one activated carbon filter 168 mounted thereon. A VFD-controlled vacuum blower 164 attached to the knockout pot 162 is used to draw the gas phase 228 from a gas vent located in an upper side of the three-phase separator 148 through the knockout pot 162 filled with water. Hydrocarbons in the gas phase 228 adhere to the water as the gas travels upwardly through the pot 162 . A wet-gas 230 that exits a gas outlet near the top of the knockout pot 162 is directed through at least one mist impinger 166 to remove water from the gas 230 and provide a dry gas 232 . The dry gas 232 is transferred to an activated carbon filter 168 to remove contaminants (e.g., remaining VOCs) therefrom in order to ensure a gas 234 that meets the regulatory standards for release to the atmosphere.
[0046] According to still another embodiment of the invention, FIG. 3 depicts the skid arrangement of a modular apparatus 300 optimally configured for recovering the valuable hydrocarbon component of sludge 14 initially having a low concentration of solids. In FIG. 3 the same reference numerals are used to indicate the same skids as those previously described with respect to the apparatus 100 depicted in FIG. 1 . Modular apparatus 300 comprises the pumping skid 102 , the shaker skid 104 , the heating skid 106 , the chemical skid 108 , the phase separator skid 110 , the gas purification skid 112 , and the oil purification skid 116 . This embodiment excludes the use of the decanter skid 114 . For sludge 14 initially having a low concentration of solids, it may be unnecessary to include a decanter centrifuge for the removal of solids.
[0047] Illustrated in FIGS. 4 and 7 , modular apparatus 300 processes pit sludge through the pumping skid 102 , the shaker skid 104 , the heating skid 106 , the chemical skid 108 , the phase separator skid 110 the gas purification skid 112 , and the oil purification skid 116 . As previously described with respect to FIG. 4 , the modular apparatus 300 processes pit sludge 10 through the pumping skid 102 , the shaker skid 104 , and the heating skid 106 to provide a heated sludge 18 .
[0048] Referring now to FIG. 7 , the heated sludge 18 is transferred to the chemical skid 108 for chemically altering the sludge 18 to break up the emulsion and promote phase separation. In FIG. 7 the same reference numerals are used to indicate the same features as those previously described with respect to apparatus 100 depicted in FIG. 5 . As previously described, the chemical skid 108 includes a plurality of chemical injection mixers 140 a - d and chemical supply tanks 142 a - d mounted thereon. Chemical addition is typically required to destabilize the emulsion and change such properties of the sludge 18 to enhance the its phase separation during the next processing step at the phase separator skid 110 . As previously described, each of the chemical injection mixers 140 a - d includes a static shear mixer having an injection point for introducing a chemical into the sludge 18 while the mixer simultaneously blends the chemical and the sludge 18 under the shearing action of the mixer. As illustrated in FIG. 7 , four chemicals are added to the heated sludge 18 as the sludge is directed through the chemical injection mixers 140 a - d . Chemical supply tanks 142 a - d store the chemicals until they are transferred via chemical lines 144 a - d to the mixers 140 a - d for injection into the sludge 18 . Preferably at least one dosing pump (not shown) in fluid communication with each of the chemical injection mixers 140 a - d is used to provide a predetermined quantity of chemical to the injection point of the mixer for introduction into the sludge 18 . Preferably, chemical injection mixers 140 a - d are thermally insulated to better maintain the sludge temperature and fluidity. Once the chemicals are introduced and blended into the heated sludge 18 , a chemically-treated sludge 302 exits the last chemical injection mixer 140 d and is subsequently transferred to the phase separator skid 110 for separating the water, oil and solid phases of the sludge 302 . Again, it should be noted that additional chemical injection mixers may be added to the chemical skid 108 for the introduction of additional chemicals into the sludge 18 .
[0049] After chemical treatment, the sludge 302 is directed to the phase separator skid 110 for separating water and solids from the oil phase of the sludge 302 . As previously described, the phase separator skid 110 includes a surge tank 146 and a three-phase separator 148 mounted thereon. The sludge 302 is fed into the vertically-oriented surge tank 146 which contains an interior plate that facilitates the small solids within the sludge to aggregate and form larger solids that settle out of the sludge 302 and accumulate in a bottom region of the surge tank 146 . Separated solids 306 that accumulate in the surge tank 146 are discharged to the solids receiving tank 150 . The surge tank 146 also provides a continuous flow of a liquid portion of the sludge 304 to the three-phase separator 148 for oil, water, gas, and solid phase separation.
[0050] The liquid portion of the sludge 304 flows into the three-phase separator 148 through an inlet located at one end of the separator 148 . After phase separation within the retention section of the three-phase separator 148 , a water-rich phase 310 is discharged to a water tank 152 , an oil-rich phase 312 is transferred to the oil purification skid 116 , and a gas phase 320 is directed to the gas purification skid 112 . Any solids 308 that may settle out of the sludge 304 and accumulated in a bottom region of the separator 148 during separation of the phases are discharged to the solids receiving tank 150 .
[0051] The oil-rich phase 312 is transferred to the oil purification skid 116 for final purification and recovery of oil therefrom having a BS&W of less than about 1 vol. %. As previously described, the oil purification skid 116 includes a disk stack centrifuge 160 mounted thereon. The oil-rich phase 312 is fed into the disk stack centrifuge 160 wherein extremely high centrifugal forces separate the very fine water emulsion and the ultra-fine solids out of the oil rich phase 312 . After phase separation, a water stream 314 , a recovered oil stream 316 , and an ultra-fine solids phase 318 are discharged from the centrifuge 160 . The recovered oil stream 316 has a BS&W less than about 1 vol. % and is commercially marketable.
[0052] The gas phase 320 is transferred to the gas purification skid 112 where the gas phase 320 is treated to remove VOCs prior to discharge into the environment. As previously described, the gas purification skid 112 preferably includes a free water knockout pot 162 , at least one mist impinger 166 , and at least one activated carbon filter 168 mounted thereon. A VFD-controlled vacuum blower 164 attached to the knockout pot 162 is used to draw the gas phase 320 from a gas vent located in an upper side of the three-phase separator 148 through the knockout pot 162 filled with water. Hydrocarbons in the gas phase 320 adhere to the water as the gas travels upwardly through the pot 162 . A wet-gas 322 that exits a gas outlet near the top of the knockout pot 162 is directed through at least one mist impinger 166 to remove water from the gas 322 and provide a dry gas 324 . The dry gas 324 is transferred to an activated carbon filter 168 to remove contaminants (e.g., remaining VOCs) therefrom in order to ensure a gas 326 that meets the regulatory standards for release to the atmosphere.
[0053] While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. | A modular apparatus having certain processing equipment mounted on portable skids that are adaptable and versatile to permit customized arrangement for oil-recovery processing of a wide range of oil-base sludge compositions in a cost-efficient manner. In one aspect, the invention is directed to a modular apparatus optimally configured for oil recovery of sludge having a high concentration of low density solids, wherein the apparatus may include a pumping skid, a shaker skid, a heating skid, a chemical skid, a phase separator skid, a gas purification skid, a decanter skid, and an oil purification skid. In another aspect, the invention is directed to a modular apparatus optimally configured for oil recovery of sludge having a high concentration of high density solids, wherein the apparatus may include a pumping skid, a shaker skid, a heating skid, a first chemical skid, a decanter skid, a second chemical skid, a phase separator skid, a gas purification skid, and an oil purification skid. In still another aspect, the invention is directed to a modular apparatus optimally configured for oil recovery of sludge having a very low solids content, wherein the apparatus may include a pumping skid, a shaker skid, a heating skid, a chemical skid, a phase separator skid, a gas purification skid, and an oil purification skid. | 53,305 |
BACKGROUND OF THE INVENTION
a) Field of the Invention
The present invention relates generally to a series hybrid vehicle (SHV), i.e., an electric vehicle (EV) mounted with a battery and generator serving as components for supplying driving power to its driving motor, and more particularly to a method of controlling power generated by the generator mounted on the SHV.
b) Description of the Related Art
Some types of EV driving system configurations are known. Among them the system called SHV includes not only a battery but also a generator as components for supplying driving power to its driving motor. The generator is typically driven by the engine. The generated power of the generator can be used both for the driving of the driving motor and for the charging of the battery.
Similar to the battery mounted on a pure EV, the battery mounted on the SHV can be naturally charged with power supplied from the exterior of the vehicle (e.g., power from a charging stand) or with power regenerated from the driving motor. Compared with the pure EV, advantageously the SHV can suppress the frequency to charge the battery with the external power, and maintain the state of charge (SOC) of the battery within a predetermined range to thus prolong its life.
Differing from the existing vehicle engine, the engine of the SHV is not directly coupled with the driving wheels. This means that the rotation of the engine is independent of the rotation of the driving wheels in the SHV, in other words, the number of rotations or the throttle angle of the engine can be controlled irrespective of the state of the rotation of the driving wheels (the state of acceleration/deceleration of the vehicle velocity). For example, compared with the conventional one, the drive of the engine with wide open throttle (WOT) in the SHV ensures a drive of the engine with a better fuel efficiency and can reduce the emission of noxious components contained in the exhaust gas from the engine.
b1) Conventional SHV
FIG. 24 depicts by way of example a configuration of the SHV. As the driving motor this SHV employs a three-phase alternating current motor 10. The output shaft of the motor 10 is coupled via a differential gear 12, etc., with driving wheels 14. Also, as the driving power source for the motor 10, there are provided a battery 16 and a generator 18. The generator 18 is driven by the mechanical output of the engine 24 whose number of rotations is increased by a speed increasing mechanism 26. By interposing such a speed increasing mechanism 26 between the engine 24 and the generator 18, the generator 18 can be rotated at a higher speed than the engine 24, thus enabling the size of the generator 18 to be reduced.
The generator 18 is a three-phase alternating current generator whose generated power is rectified by a rectifier 22. In the powering state, the generated power rectified by the rectifier 22 is converted into a three-phase alternating current by an inverter 20 and is thereupon fed as the driving power into the motor 10. If at that time the generator 18 cannot independently supply the power required for the driving of the motor 10, the deficiency of the generated power relative to the required motor driving power is supplemented by the discharged power of the battery 16. Similar to the generated power of the generator 18, the discharged output of the battery 16 is converted into a three-phase alternating current by the inverter 20 and then supplied as the driving power into the motor 10. On the contrary, if a larger generated power than the required motor driving power is obtained, then the surplus of the generated power with respect to the required motor driving power is used to charge the battery 16. When the motor 10 is in a regeneration braking state, the regeneration power from the motor 10 is rectified by the inverter 20 and thereafter used to charge the battery 16.
The action of the motor 10 is controlled by the controller 28. Based on the accelerator angle θ A indicating the acceleration demand from the driver, the controller 28 first determines a reference torque T ref for the motor 10. At that time the controller 28 refers to and monitors the number of rotations N detected by a number-of-rotation sensor 30. The controller 28 then generates switching signals (e.g., a pulse width modulation signal: PWM signal) in response to the thus determined reference torque T ref . The controller 28 supplies the thus generated switching signals to switching devices constituting the inverter 20. Through the series of procedures, the acceleration in accordance with the torque corresponding to the reference torque T ref , that is, with the accelerator angle θ A , can be realized.
The SHV requires that the fuel efficiency of the engine 24 be optimized and the emission from the engine 24 be minimized. Since frequent or sharp changes in the number of rotations of the engine 24 increase emissions from the engine 24, the generated power from the generator 18 must be constant in order to minimize emissions from the engine 24. However with the generated power of the generator 18 constant, the charging and discharging of the battery 16 may become unbalanced. For example, when the generated power is constant and the motor 10 continues to be driven with a large output over a long period of time, the charge/discharge balance may rapidly slant to the discharge side and therefore the SOC of the battery 16 is reduced since the state lasts for a long period of time in which the power required for the driving of the motor 10 is not to be supplied solely from the generator 18. The opposite will also happen if the motor continues to be driven at a low output for a long period of time. Accordingly, if the generated power of the generator 18 is made constant, the SOC is inevitably subject to a variation over a wide range. Since the life of the battery 16 is prolonged as long as the SOC is controlled to lie within a relatively smaller and predetermined range, a constant generated power of the generator 18 will shorten the life of the battery 16.
To relieve this problem, it is preferred to introduce the target control for the generated power of the generator 18, with the restriction of the variation of the target power to be generated of the generator 18 so as not to cause frequent and sharp changes in the number of rotations of the engine 24. For example, the high-speed target power and low-speed target power are prepared as the target power to be generated. When the number of rotations N of the motor 10 detected by the rotation sensor 30 equals or exceeds a predetermined value, use is made of the high-speed target power, whereas with less than the predetermined value the low-speed target power is used. The number of rotations of the engine 24 and the generated power of the generator 18 can be controlled by regulating the throttle angle θ th of the engine 24 and the field current I f . of the generator 18. This high/low switching will allow the reduced change in the SOC caused by the change of the motor output than that in the constant power driving of the generator 18.
b2) Improvement Already Proposed by the Applicant
However a mere switching the target power in accordance with the number of the rotations of the motor 10 would allow the number of rotations of the engine 24 to be subjected to a frequent or abrupt change e.g., when acceleration and deceleration are frequently repeated. The present applicant has already proposed, in 1993, a method complying with the principle shown in FIG. 25 as a method capable of solving these problems (Japanese Patent Application No. Hei 5-29085).
This principle includes that an inverter input power=motor output power/inverter efficiency, which is averaged in a certain averaging period, and the resultant average is used as the target of the generated power (target power to be generated) of the generator 18 in the next averaging period. For example, the averaged inverter input power in the averaging period B is used as the target power in the next averaging period C, and the averaged inverter input power in the averaging period C is used as the target power in the next averaging period D. In this manner, the target power to be generated is updated in accordance with the averaged inverter input power and for each averaging period.
To realize this principle, the charge/discharge balance of the battery 16 must be appropriately monitored. To this end, the controller 28 selectively monitors a motor voltage V M detected by a voltage sensor 32, a motor current I M detected by a current sensor 34, an inverter input current I INV detected by a current sensor 36, a battery voltage V B detected by a voltage sensor 38, a battery current I B detected by a current sensor 40, etc. On the basis of these detected values, the controller 28 calculates the generated power of the generator 18, input/output power into and from the inverter 20, and the charged/discharged power of the battery 16 for each averaging period. From these results, the controller 28 evaluates the balance of charge/discharge of the battery 16. By simultaneously calculating the accumulated value of the charge/discharge current of the battery 16 and using the initial value of the SOC, the SOC of the battery 16 can be monitored. In response to these power balance and SOC values, the controller 28 controls the number of rotations of the engine 24 and the generated power of the generator 18.
According to such a principle, the variation of the motor output power can be rapidly followed by the generated power of the generator 18 and hence the charge/discharge of the battery 16 can be suppressed compared with the control making the generated power constant or with the control switching the target power in compliance with the high-speed or low-speed, whereby the SOC of the battery 16 can be maintained at all times within the range of the target and hence the life can be prolonged. Due to the total lack of any possibility to cause a variation in the number of rotations of the engine 24 in a shorter period than the averaging period, the emission is prevented from remarkable increasing.
b3) Problems which Have Newly Arisen
Disadvantageously, the control by such principle entails a control delay on account of the averaging operation. More specifically, since the average inverter input power in a certain averaging period is used as the target power to be generated in the next averaging period, the change of the generated power is slightly delayed with respect to the change of the inverter input power, as shown in FIG. 25.
This delay firstly will confer a sense of incongruity on the driver in view of the drive feeling. Take as an example a case where the driver has depressed the accelerator pedal and thereupon has immediately released the accelerator pedal. In this case, a torque is imparted to the motor 10 in accordance with the depressing of the accelerator pedal, with the result that the inverter input power is increased. When the inverter input power is increased in a certain averaging period, the target power in the next averaging period is changed into a larger value than the target power in that averaging period. If the driver has already released the accelerator pedal before entering that next averaging period, the number of rotations of the engine 24 is increased irrespective of the fact that there is no depressing of the accelerator pedal by the driver. Although the increase in the number of rotations of the engine 24 will not cause any danger with regard to the driving of the vehicle, since in the SHV the engine 24 is not directly coupled with the driving wheels 14, this phenomenon, which was never experienced in the existing vehicle having only the engine, may impart a sense of incongruity to the driver accustomed to the existing vehicle.
The delay of the change in the generated power with respect to the change in the inverter input power will secondly be an obstacle to the improvement of the power efficiency. For example, the battery 16 is forced to discharge in the averaging period (e.g., averaging period B) in which the inverter input power exceeds the generated power. Conversely, the battery is charged by the generated power in the averaging period (e.g., averaging period D) in which the inverter input power is less than the generated power. At the time of these charge/discharge, a loss will occur due to the charge/discharge efficiency of the battery 16, and therefore the power efficiency lowers when estimated for the overall vehicle.
Incidentally by setting the target power to be generated on the basis of the moving average of the inverter input power, the above delay can be diminished. That is, this technique will enable the delay of change in the generated power with respect to the change in the inverter input power to be reduced to a degree of 1/2 of the moving averaging period. Simultaneously it is possible to remove the high-frequency fluctuation contained in the inverter input power from the target power to be generated, namely, to prevent the high-frequency fluctuation from occurring in the number of rotations of the engine 24. However, the setting of the target power on the basis of the moving average will cause a problem that the target power always varies in accordance with the variation of the inverter input power. It will be appreciated that the target power becomes constant within at least a single averaging period in the foregoing method in which the average inverter input power in a certain averaging period is used as the target power in the next averaging period. In other words, the method of setting the target power on the basis of the moving average is liable to cause deterioration of the emission or fuel efficiency arising from the change in the number of rotations of the engine 24.
SUMMARY OF THE INVENTION
It is therefore the first object of the present invention to avoid or alleviate delays in control due to averaging operations, by setting or modifying target powers to be generated, on the basis of a motor output power, the state of load of a battery, etc., thus improving the drive feeling and power efficiency. The second object of the present invention lies in realizing a more accurate, simple and rapid control of a generated power as well as a control adaptable to variations of the motor output power.
The present invention is applied to a series hybrid vehicle (SHV) equipped with an engine, a generator, a battery, and a motor, the generator driven by the engine, the motor driven by the generated power of the generator and a discharged power of the battery, the battery being charged by the generated power. According to an aspect of the present invention, there is provided a method executed in the SHV and comprising the first step of controlling, for each of successively coming periods, the generated power in accordance with a target power to be generated; the second step of detecting, while controlling the generated power, a plurality of times in a single period, a prediction base quantity implying both an instantaneous motor output of the motor and the tendency of the instantaneous motor output; and the third step of determining, on the basis of the prediction base quantity, the target power to be generated in coming periods.
Thus in the present invention, the tendency of the instantaneous motor output in a certain period is reflected on the target to be generated in the subsequent period, whereupon in that subsequent period the difference between the actual generated power and the instantaneous motor output will diminish compared with the prior art. This is equivalent to a reduction of delays in control which have been hitherto often caused by the averaging operations. Accordingly the present invention is capable of realizing an improvement in the drive feeling and power efficiency.
The first example of the prediction base quantity can be an approximation function approximating variations in the instantaneous motor output power. When using such a prediction base quantity, in the third step there is first estimated an expectation of an average motor output power in a coming period or periods by use of the approximation function determined for the periods which have already elapsed. The expectation may be estimated by, e.g., substituting for the above approximation function a point of time lying in the middle of each of the coming periods. Then, on the basis of the thus estimated expectation, the target power to be generated in the corresponding one of coming periods is determined.
In particular the use of the method of least-squares approximation for the derivation of the approximation function would heighten the accuracy with which the expectation is estimated, thus lessening the control error in those coming periods. Also realized are a simplified estimating operation and a rapid control in the case of using, as the above approximation function, a function joining the instantaneous motor output powers at a plurality of (e.g., two) points of time lying within the period which has already elapsed. The two points to be employed in this case can be the start timing and the end timing of the period which has already elapsed. A linear function may be an approximation function of the simplest type and hence allowing the simplest estimating operation.
The second example of the prediction base quantity can be the first index value indicating the status of acceleration/decleration, i.e., the state of positive/negative acceleration of the motor at the most recent point of time. When using such a prediction base quantity, preferred procedures employable in the third step may include firstly a procedure for modifying the target power to be generated and secondly a procedure for interrupting the control period.
With the adoption of the procedure for modifying the target power to be generated, in the third step the instantaneous motor output powers are first averaged for each period to detect the average motor output power. Then the quantity obtained by subjecting the average motor output power in the period which has already elapsed to a modification in accordance with the first index value is set as the target power to be generated in a coming period or periods. For example if the instantaneous motor output power or the required motor output power has an increasing tendency in the vicinity of the transition from a certain period to the next period, the target power to be generated in that next period will be modified upward with respect to the motor average output power, whereas if it has a decreasing tendency, it is modified downward. In this manner the modification of the target power can be carried out.
The first way of modifying the target power to be generated upon the setting of the generated power in the next period is to utilize the results of comparison between the output zone, within which lies the average motor output power in the period which has already elapsed, and the positive/negative acceleration zone, within which lies the state of the positive/negative acceleration at a recent period of time. This method will allow the contents of the modifications to be determined in accordance with combinations of the output zone, within which lies the average motor output power in the period which has already elapsed, and the positive/negative acceleration zone, within which lies the state of the positive/negative acceleration at a recent period of time. More specifically the target power to be generated is modified into a larger value than that before modification when that output zone is one indicating a small output and that positive/negative acceleration zone is one indicating a high acceleration, whereas the target power is modified into smaller value than that before modification when that output zone is one indicating a large output and that positive/negative acceleration zone is one indicating a low acceleration. This method will also enable the target power after the modification to be fixed to a constant which is predetermined by e.g., the ratio relative to the permitted maximum generated power of the generator, for each of the combinations of the zones, thus contributing to the realization of a stable control preventing an occurrence of superposed noise.
The second method of modifying the target power to be generated upon the setting of the generated power in the next period is to modify the target power in accordance with the amount of variations relative to the first index value indicating the positive/negative acceleration of the motor at the most recent point of time, of the second index value indicating the state of average positive/negative acceleration of the motor in that period which has elapsed. This method will ensure a simplified control operation and accurate control.
In the case of using the first index value as the prediction base quantity and of employing the procedure to interrupt the control period, it is first detected, in the third step and on the basis of the second index value, that the first index value has changed by a predetermined degree or more. It is to be noted that the second index value herein is a quantity indicating the state of the average positive/negative acceleration of the motor during a preceding predetermined period of time, which differs slightly from the foregoing in meaning. Afterwards if the first index value has changed by the predetermined degree or more, the period just about to elapse is forcibly interrupted and a new period is forcibly started. Then, the instantaneous motor output powers are averaged for each period to detect the average motor output power in that period. Thereafter at the point of time when the new period has been started, the average motor output power in the periods which have already elapsed is set as the target power to be generated in that new period.
The adoption of such a procedure eliminates the need to allow for an abrupt change in the instantaneous motor output power or the required motor output power upon designing the control period (averaging period), which will contribute to a longer averaging period for the instantaneous motor output power than in the prior art. The longer averaging period will lead to an extension of the period of time during which the engine speed is constant, resulting in an improvement in the fuel efficiency and emission. It is to be appreciated that depending on the nature of the first index value, the first index values may be averaged for each period to thereby determine the second index values in the next period.
The third example of the prediction base quantity can be the third index value indicating the state of charge/discharge of the battery at the recent point of time. For the use of such a prediction base quantity, it is detected in the third step, on the basis of the fourth index value, that the third index value has changed by a predetermined degree or more. The fourth index value is a quantity indicating the average state of charge/discharge of the battery during a preceding predetermined period of time. Then, if the third index value has changed by the predetermined degree or more, the period just about to elapse is forcibly interrupted and a new period is forcibly started. Furthermore the instantaneous motor output powers are averaged for each period to thereby detect the average motor output power in that period. Then, at the point of time when a new period has been started, the average motor output power in the periods which have already elapsed is set as the target power to be generated in that new period.
The adoption of such a prediction base quantity enables the control period to be altered in response to an abrupt change in the state of load of the battery, thus eliminating the necessity of allowing for the abrupt change in the state of load of the battery upon designing the averaging period for the instantaneous motor output power. As a result of this, the averaging period of time for the instantaneous motor output power can be made longer than in the prior art, contributing to the improvement in the fuel efficiency and emission.
Additionally, the instantaneous motor output power may be detected on the basis of the current flowing through the motor and the voltage applied to the motor. In this case there is no need to use the quantity which has not been hitherto used for the control of generated power, resulting in less alteration in the conventional control procedure and apparatus. The same advantages can also be obtained by the detection on the basis of the discharged current of the battery and the voltage of the battery. When the instantaneous motor output power is detected on the basis of the motor output torque (including the accelerator angle, reference torque, etc.) and the number of rotations of the motor, the inertia of the motor will serve to smooth the number of rotations of the motor, and hence a stabler control is realized. It is natural that the same functions can be obtained by subjecting the detected values to the moving averaging operation even if the instantaneous motor output power is detected by use of quantities other than these.
The examples of the first index value are:
a) the instantaneous motor output at the most recent point of time or its moving average;
b) the number of rotation of the motor at the most recent point of time or its moving average;
c) the speed of the series hybrid vehicle at the most recent point of time or its moving average;
d) the torque required for the motor at the most recent point of time or its moving average; and
e) the amount of depressing the accelerator pedal at the most recent point of time or its moving average.
The examples of the second index value are:
a) average output of the motor in the period which has already elapsed; p1 b) the average number of rotation of the motor in the period which has already elapsed;
c) the average speed of the series hybrid vehicle in the period which has already elapsed;
d) the average torque required for the motor in the period which has already elapsed; and
e) the average amount of depressing the accelerator pedal in the period which has already elapsed.
The examples of the third index value are;
a) the discharged current of the battery at the most recent point of time or its moving average;
b) the integrated value of the discharged current of the battery in the period which is just about to elapse; and
c) the state of charge of the battery at the most recent point of time.
The examples of the fourth index value are:
a) 0; and
b) the state of charge of the battery at the earliest point of time after the end of the period which has already elapsed.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects, advantages and features of the present invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a flowchart showing a method of controlling the generated power in accordance with the first embodiment of the present invention;
FIG. 2 is a timing chart showing the principle of the first embodiment;
FIG. 3 is a timing chart showing the effects of the first embodiment through the comparison with the prior art;
FIG. 4 is a flowchart showing a method of controlling the generated power in accordance with the second embodiment of the present invention;
FIG. 5 is a timing chart showing the principle of the second embodiment;
FIG. 6 is a flowchart showing a method of controlling the generated power in accordance with the third embodiment of the present invention;
FIG. 7 is a timing chart showing the principle of the third embodiment;
FIG. 8 to 13 are flowcharts respectively showing methods of controlling the generated power in accordance with the fourth to ninth embodiments of the present invention;
FIG. 14 is a timing chart showing the principle of the ninth embodiment;
FIG. 15 to 23 are flowcharts respectively showing methods of controlling the generated power in accordance with the tenth to eighteenth embodiments of the present invention; FIG. 24 is a block diagram showing, by way of example, a configuration of the SHV; and FIG. 25 is a timing chart showing the principle of a method of controlling the generated power in accordance with a prior art example.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred exemplary embodiments of the present invention will now be described with reference to the accompanying drawings. It is to be appreciated that the present invention can be carried out under the configuration depicted in FIG. 24 and therefore the following description is given on the basis of the configuration of FIG. 24, but the present invention is not intended to be limited to the FIG. 24 configuration.
a) Estimate of Inverter Input Power (Motor Output Power) in Next Period
a1) First Embodiment Referring to FIG. 1 there is depicted a flow of procedures for controlling the generated power among the procedures performed by a controller 28 in the first embodiment of the present invention.
In this embodiment the controller 28 first resets a variable i to 0 (100) and samples an instantaneous inverter input power P i five times (102, 104, 108). The sampling period is Δt (106). By use of the least squares method the controller 28 approximates to a line L depicted in FIG. 2, which is the instantaneous inverter input power P i for five timing intervals obtained by the sampling (110). In other words, using the following expression (1), a "t" intercept (t m , P m ) and a gradient b of the line L are calculated. Here among the variables representing the "t" intercept, t m is an average (an average sampling timing) of sampling timings t i , and P m is an average (an average inverter input power) of the instantaneous inverter input powers P i sampled at the sampling timing t i . ##EQU1##
The line L thus obtained is a line approximating variations with time of the instantaneous inverter input power P for an averaging period A depicted in FIG. 2. In this embodiment the line A approximating the inverter input for period A is used as a line indicating the target power for period B. That is, use is made of the line L in order to indicate the target power to be generated in the next averaging period B. Incidentally in this embodiment five timings are used for approximating the instantaneous inverter input power P i Thus in the following description, t 1 to t 5 represent five sampling timings falling within the averaging period A and t 6 to t 10 represent sampling timings falling within the averaging period B.
More specifically, from the following expression (2) the controller 28 first finds an average of the sampling timings t 6 to t 10 , namely a timing t for which the expectation is to be estimated (112). Then the controller 28 substitutes, for the expression (3) defining the line L, both the timing t for which the expectation is to be estimated and "t" intercept (t m , P m ) (114). P derived from this arithmetic operation represents an expectation of the inverter input power at the central timing t 8 in the period B. As the expectation P the controller 28 sets the target power to be generated in the period B and controls the generator 18 on the basis of the target power (116). Thereafter the action of the controller 28 returns to the step 100. ##EQU2##
Thus in this embodiment the tendency of the inverter input power is reflected in the target power to be generated. Accordingly, as shown in FIG. 3, this embodiment has less difference between the inverter input power and the generated power compared with the control method in which the average inverter input power P m in the previous averaging period is set as the target power. In other words, its ability to set the target power with less errors will prevent the charging and discharging of a battery 16 from occurring and reduce the amount of charged and discharged currents. This will result in advantages that variations of SOC of the battery 16 are suppressed to prolong its life and that the decrease in the power efficiency on an overall vehicle basis arising from the charge and discharge loss is prevented.
Furthermore, since the engine speed is constant in a single averaging period, hardly any variations occur in the engine speed and their attendant deteriorations in both the fuel efficiency and the emission, compared with the control method in which set as the target power is a moving average of the instantaneous inverter input power P i .
Additionally, due to the fact that the line approximating the inverter input for period A is determined by use of the least squares approximation, it is possible to accurately estimate the expectation of the inverter input power at the timing t 8 , which will contribute to accurate control of the power to be generated.
a2) Second Embodiment
Referring to FIG. 4 there is depicted a flow of actions which the controller 28 executes for controlling the generated power in the second embodiment of the present invention. In this embodiment the controller 28 samples the instantaneous inverter input power P i at both the start timing and the end timing of the respective averaging periods, each having a duration t (200 to 204). In the diagram, P 1 and P 2 represent sampled values at the start timing and the end timing, respectively, of the averaging period. By use of the thus obtained two sampled values P 1 and P 2 , the controller 28 determines an approximating line L depicted in FIG. 5 (206). More specifically, for respective periods A, B, . . . , the controller 28 finds the inverter input power P 1 at the start timing and the inverter input power P 2 at the end timing to thereby determine the following expression representing the line L joining P 1 and P 2 .
P=(P.sub.2 -P.sub.1)/t*x+P.sub.1 (4)
For the thus determined expression (4) the controller 28 substitutes a central timing t/2 +t in the next period B designated at t B in FIG. 5 (208). The resultant expected inverter input power P is used as the target to control the generated power of the generator 18 in the period B (210).
This will contribute to the realization of substantially the same effects as the first embodiment by this embodiment. It is to be particularly understood that the errors in generated power control may be slightly increased due to the lower approximation accuracy compared with the least squares approximation in the first embodiment. On the contrary, this embodiment will realize a speedup of the control due to a lower number of operations and allow a provision of additional functions by making use of the reduction in the load imposed on the controller 28.
b) Modification of Target Power by Zone Comparisons
b1) Third Embodiment
Referring to FIG. 6 there is depicted a flow of actions which the controller 28 executes for controlling the generated power in the third embodiment of the present invention. In this embodiment, the controller 28 samples the instantaneous inverter input power P i a plurality of times during the respective averaging periods having a duration t (300, 302), and using the results finds the average P m of the sampled value P i in the averaging period (304). Unless the thus found average inverter input power P m and the accelerator angle θ A at that point of time satisfy the predetermined conditions (306 to 314), in the same manner as the prior art techniques, the controller 28 uses the average inverter input power P m as the target for controlling the generated power of the generator 18 in the next averaging period (324 to 330).
This embodiment is characterized in that the target power to be generated is accordingly increased or decreased when the combination of the zone within which the average inverter input power P m falls and the zone within which the accelerator angle θ A falls at the end of each averaging period results in a predetermined combination.
Referring now to Table 1, consider a case, by way of example, where the average inverter input power P m is less than 20% of the permitted maximum generated power of the generator 18 (306). In this case, if the accelerator angle θ A is not less than 50% at the end of the averaging period (308), the instantaneous inverter input power P i in the next averaging period can be estimated to increase compared to before. Thus the controller 28 corrects the target power to increase it up to 38% of the permitted maximum generated power (316). In the same manner, if the average inverter input power P m is 25% or over and less than 50% of the permitted maximum generated power of the generator 18 (306), with the accelerator angle θ A of 75% or over at the end of the averaging period (310), then the controller 28 will correct the target power to increase it up to 63% of the permitted maximum generated power (318). In both cases, the target power exceeds the average inverter input power P m (the hatched area in the lower right region of Table 1).
Conversely consideration will be given of a case where the average inverter input power P m is 50% or over and less than 75% of the permitted maximum generated power of the generator 18 (306). In this case if the accelerator angle θ A is less than 25% at the end of the averaging period (312), the instantaneous inverter input power P i in the next averaging period is expected to decrease compared to before. Then the controller 28 corrects the target power to decrease it down to 38% of the permitted maximum generated power (320). Similarly, providing that the average inverter input power P m is more than 75% of the permitted maximum generated power of the generator 18 (306) with the accelerator angle θ A less than 50% at the end of the averaging period, the controller 28 corrects the target power to decrease it down to 63% of the permitted maximum generated power (322). In both cases the target power is less than the average inverter input P m (the hatched area in the upper left region of Table 1).
TABLE 1______________________________________ZONE CORRECTION IN THIRD EMBODIMENT______________________________________ ##STR1##______________________________________ ##STR2## ##STR3## θ.sub.A : ACCELERATOR ANGLE
In the third embodiment in this manner, the target power to be generated is set greater than the average inverter input power P m and in accordance with the average inverter input power P m and the accelerator angle θ A when the zone within which the average inverter input power P m falls is a zone indicating "motor output power is small" and the zone within which the accelerator angle θ A falls is a zone indicating "significant acceleration requirement is present". On the contrary, the target power to be generated is set smaller than the average inverter input power P m and in accordance with the average inverter input power P m and the accelerator angle θ A providing that the zone within which the average inverter input power P m lies is a zone indicating "motor output power is large" and the zone within which the accelerator angle θ A lies is a zone indicating "significant acceleration requirement is absent".
Accordingly, as clearly illustrated in FIG. 7, there lies less difference between the instantaneous inverter input power P i and the generated power of the generator 18 as compared with the prior art. That is, it is judged from the accelerator angle θ A indicating the acceleration requirement for the motor 10 whether the instantaneous inverter input power P i has an increasing tendency or a decreasing tendency at the end of the averaging period, and the results are reflected on the setting of the target power to be generated, whereby the target power can be set with fewer errors. This will result in appropriate maintenance of the SOC of the battery 16 allowing its life to be prolonged and a suppression of the charge and discharge loss of the battery 16 enabling the vehicle power efficiency to be improved.
Moreover the constant engine speed within a single averaging period will prevent variations in engine speed and their attendant deterioration of the fuel efficiency and emission from occurring, compared with the case where the moving average of the instantaneous inverter input power P i is set as the target power to be generated. In addition, the use of fixed values, such as 38%, 63%. etc., as well as zoning upon the increase and decrease of the target power, will allow the control of generated power to be far less influenced by the superposed noise which may appear in the average inverter input power P m .
b2) Fourth Embodiment
Referring to FIG. 8 there is depicted a flow of actions the controller 28 executes for controlling the generated power in the fourth embodiment of the present invention. Among the actions in this embodiment steps 400 to 406 and 416 to 430 are respectively identical with the steps 300 to 306 and 316 to 330 in the third embodiment. This embodiment differs from the third embodiment in that a number of motor rotations N or a vehicle velocity v equivalent thereto are zoned, not the accelerator angle θ A in steps 408 to 414 corresponding to the steps 308 to 314 in the third embodiment. More specifically, as shown in table 2, this embodiment employs different target powers to be generated for respective zones v <25%, 25%≦v<50%, 50%≦v<75%, 75%≦v. v=100% is a vehicle velocity corresponding to the permitted maximum number of motor rotations. The hatched areas in the upper left of Table 2 represent zone combinations with which the target power is set to be larger than the average inverter input power P m , and the hatched areas in the lower right of Table 2 represent zone combinations with which the target power is set to be smaller than the average inverter input power P m .
TABLE 1______________________________________ZONE CORRECTION IN FOURTH EMBODIMENT______________________________________ ##STR4##______________________________________ ##STR5## ##STR6##
Thus, according to this embodiment, for the execution of the same processing as the third embodiment, use is made of the number of motor rotations N or the vehicle velocity v which is one of the elements determining the output power of the motor 10, thereby ensuring the same effects as in the third embodiment. Furthermore the number of rotations N and the vehicle velocity v are smoothed by the inertia of the motor 10, ensuring stabilized zoning actions in the steps 408 to 414 compared with the third embodiment.
b3) Fifth Embodiment
Referring to FIG. 9 there is depicted a flow of actions the controller 28 performs for controlling the generated power in the fifth embodiment of the present invention. Among the actions in this embodiment, steps 500 to 506 and 516 to 530 are respectively identical with the steps 300 to 306 and 316 to 330 in the third embodiment.
This embodiment differs from the third embodiment in that the instantaneous inverter input power P i is zoned, not the accelerator angle θ A , in steps 508 to 514 corresponding to the steps 308 to 314 in the third embodiment. More specifically, as is apparent from Table 3, this embodiment employs different target powers to be generated for the zones P i <25%, 25%≦P i <50%, 50%≦P i <75%, 75%≦P i . The hatched areas in the upper left in Table 3 represent zone combinations allowing the target power to be set larger than the average inverter input power P m , and the hatched areas in the lower right in Table 3 represent zone combinations allowing the target power to be set smaller than the average inverter input power P m .
TABLE 1______________________________________ZONE CORRECTION IN FIFTH EMBODIMENT______________________________________ ##STR7##______________________________________ ##STR8## ##STR9## P.sub.i : INSTANTANEOUS INVERTER INPUT POWER
Thus, according to this embodiment, for the execution of the same processing as the third embodiment, use is made of both the output power of the motor 10 and the instantaneous inverter input power P i reflecting its tendency, thereby ensuring the same effects as in the third embodiment. In addition the use of the instantaneous inverter input power P i in this embodiment will eliminate the need to input the external variables such as accelerator angle θ A .
c) Modification of Target Power by Modification Terms
c1) Sixth Embodiment
Referring to FIG. 10 there is depicted a flow of actions the controller 28 performs in the sixth embodiment of the present invention. This embodiment is common to the third embodiment in that use is made of the value of the accelerator angle θ A at the end of the averaging period for setting the target power to be generated in the next averaging period. However, this embodiment differs from the third embodiment in that the modification terms are substituted for the target power setting expression instead of zoning and zone comparisons.
The controller 28 first samples the instantaneous inverter input power P i and the accelerator angle θ A a plurality of times for respective averaging periods having a duration t (600 to 604). Then the controller 28 finds the average inverter input power P m and the average accelerator angle θ Am in the averaging period (606, 608). Thereupon the controller 28 detects the accelerator angle θ A at the point of time immediately before setting the target power to be generated (610). Subsequently the controller 28 finds from the following expression (5) the target power P in the next average period (612). At that time, as is apparent from the expression (5), added to the average inverter input power P m is a modification term including the average accelerator angle θ Am found in the step 608 and the accelerator angle θ A found in the step 610. It is to be noted that k included in the modification term is a coefficient determining the response of the target power P for the accelerator angle θ A .
P=P.sub.m +k(θ.sub.A -θ.sub.Am) (5)
Thus according to this embodiment, the same effects as in the third embodiment can be obtained using the simple expression (5). Additionally the use of the expression (5) will allow the tendency of the accelerator angle θ A to be positively reflected in the power generation control more closely than the third embodiment, consequently heightening the effects such as reduction of errors in the control of the generated power and therefore the improvement of the fuel efficiency and emission, as well as the maintenance of the SOC and the prolonging of the life of the battery.
c2) Seventh Embodiment
Referring to FIG. 11 there is depicted a flow of actions the controller 28 executes for controlling the generated power in the seventh embodiment of the present invention. Among the actions in this embodiment, steps 700, 704 and 706 are identical with the steps 600, 604 and 606 in the sixth embodiment. In this embodiment, steps 702, 708, 710 and 712, corresponding to the steps 602, 608 and 610 and 612 in the sixth embodiment, are intended for the vehicle velocity v or the number of motor rotations equivalent thereto instead of the acceleration angle θ A . Thus according to this embodiment, the same effects as in the sixth embodiment can be obtained. Furthermore the vehicle velocity for use in this embodiment is subjected to smoothing by the inertia of the motor 10, which will contribute to the stabilized control of generated power.
c3) Eight Embodiment
Referring to FIG. 12 there is depicted a flow of actions the controller 28 executes for controlling the generated power in the eighth embodiment of the present invention. Among the actions in this embodiment, steps 800 to 804 are respectively identical with the steps 600, 604 and 606 in the sixth embodiment. This embodiment does not include steps corresponding to the steps 602 and 608 in the sixth embodiment, but includes steps 806 and 808 corresponding respectively to the steps 610 and 612 and intended for the instantaneous inverter input power P i instead of the accelerator angle θ A . In consequence this embodiment will ensure the same effects as obtained in the sixth embodiment and eliminate the need to input the external variables such as the accelerator angle θ A .
d) Modification of Averaging Period
d1) Ninth Embodiment
Referring to FIG. 13 there is depicted a flow of actions the controller 28 executes for controlling the generated power in the ninth embodiment. Different from the third to eighth embodiments, this embodiment subjects the averaging period to a modification without modifying the target power to be generated.
The controller 28 first samples the instantaneous inverter input power P i and the accelerator angle θ A a plurality of times for respective averaging periods having a duration t (900 to 904). From the results, the controller 28 finds the average inverter input power P m and the average accelerator angle θ Am for the averaging period (906, 908). At that point of time the controller 28 uses as the target power the average inverter input power P m in the conventional manner to control the generated power (910). Afterwards during the next control period of time t, i.e., by the end of the averaging period (916), the controller 28 repeats the actions through steps 906 to 914 unless the accelerator angle θ A varies remarkably (918).
By the time the current averaging period comes to an end after starting the control of the generated power with the average inverter input power P m obtained in step 906 as its target (918), if the accelerator angle θ A has varied remarkably (916), the controller 28 will operate both the average inverter input power P m and the average accelerator angle θ Am with respect to the period during which the actions (steps 910 to 918) indicated by @ in the diagram are executed (920, 922). For the execution of this action the controller 28 samples the instantaneous inverter input power P i and accelerator angle θ A in steps 912 and 914 previous to the step 916. Then the controller 28 starts the action indicated by @ using new average inverter input power P m and average accelerator angle θ Am derived from the operation.
In the diagram reference letter x denotes an infinitesimal value for judging the degree of change of the accelerator angle θ A . If θ Am -x<θ A <θ Am +x is established, then it is judged that the accelerator angle θ A has not changed remarkably, whereas with θ A <θ Am -x or θ Am +x<θ A the accelerator angle θ A is judged to have changed remarkably.
Thus, according to the present invention, when a sharp change has occurred in the accelerator angle θ A , the target power to be generated is updated without waiting for the end of the current averaging period whereby the difference between the inverter input power and the generated power will be diminished compared with the prior art as shown in FIG. 14. In other words, this embodiment makes it possible to appropriately set the target power updating timing since it monitors the accelerator angle θ A and therefore the tendency of the required output power for the motor 10 and allows the results to reflect in the target power. In the same manner as the first embodiment, this will result in, for example, an prolonged life of the battery 16 due to the maintenance of its SOC, the prevention of the loss in the vehicle power efficiency on account of the charge and discharge loss of the battery 16, and the improvement of the fuel efficiency and emission. Furthermore its ability to respond to the sharp change of the accelerator angle θ A will prevent the battery 16 from being overdischarged or being overcharged irrespective of abrupt acceleration or abrupt braking of the vehicle. Accordingly this embodiment will eliminate the necessity of setting shorter averaging periods to cope with the abrupt changes, thus making it possible to suppress the changes in the engine speed with longer averaging periods and to further improve the emission and fuel efficiency.
d2) Tenth Embodiment
Referring to FIG. 15 there is depicted a flow of actions the controller 28 executes for controlling the generated power in the tenth embodiment of the present invention. The contents of steps 1000 to 1012 and 1016 to 1022 in this embodiment are substantially the same as those of the steps 900 to 912 and 916 to 922 in the ninth embodiment.
In step 1014, however, the controller 28 not only samples the accelerator angle θ A as in the step 914 but also calculates a moving average of the sampled accelerator angle θ A . The accelerator angle θ A being generally liable to the abrupt changes, the execution of such moving averaging operation will enable high-frequency fluctuation components to be removed from the accelerator angle θ A , contributing to a stabler control.
d3) Eleventh Embodiment
Referring to FIG. 16 there is depicted a flow of actions the controller 28 executes for controlling the generated power in the eleventh embodiment of the present invention. The contents of steps 1100 to 1122 in this embodiment are substantially the same as those of the steps 900 to 922 in the ninth embodiment.
It is to be appreciated that the steps 1102, 1108, 1114, 1116 and 1122 of this embodiment employ the vehicle velocity v or the number of rotations of the motor 10 equivalent thereto in lieu of the accelerator angle θ A in the steps 902, 908, 914, 916 and 922 of the ninth embodiment. More specifically, if the vehicle velocity v has abruptly changed relative to the average vehicle velocity v m when the action indicated by @ is being executed (1116), the target power to be generated is updated (1110) in accordance with the average dissipation power P m during the execution of the action indicated by @ (1120).
Thus, according to this embodiment, the same effects as in the ninth embodiment can be obtained. In addition the smoothing of the vehicle velocity v by the inertia of the motor 10 will contribute to a stabler control.
4) Twelfth Embodiment Referring to FIG. 17 there is depicted a flow of actions the controller 28 executes for controlling the generated power in the twelfth embodiment of the present invention. The contents of steps 1200 to 1208, 1212 and 1214 in this embodiment are respectively the same as those of the steps 900, 904, 906, 910, 912, 918 and 920 in the ninth embodiment.
However, this embodiment does not execute the actions corresponding to the steps 902, 908, 914 and 922 in the ninth embodiment but includes step 1210 corresponding to the step 916 in which the instantaneous inverter input power P i is compared with the average inverter input power P m for judgment. Thus, this embodiment will ensure the same effects as in the ninth embodiment and eliminate the need to use the external variables such as accelerator angle θ A and vehicle velocity v.
d5) Thirteenth Embodiment Referring to FIG. 18 there is depicted a flow of actions the controller 28 executes for controlling the generated power in the thirteenth embodiment of the present invention. The contents of steps 1300 to 1306 and 1310 to 1314 in this embodiment are substantially the same as those of the steps 1200 to 1206 and 1210 to 1214 in the twelfth embodiment. This embodiment differs from the twelfth embodiment in that executed in step 1308 are not only the sampling of the instantaneous inverter input power P i but also the moving averaging operation.
The instantaneous inverter input power P i being generally liable to the abrupt changes, the execution of such a moving averaging operation will enable high-frequency fluctuation components to be removed from the instantaneous inverter input power P i , contributing to a stabler control.
d6) Fourteenth Embodiment
Referring to FIG. 19 there is depicted a flow of actions the controller 28 executes for controlling the generated power in the fourteenth embodiment of the present invention. The contents of steps 1400 to 1408, 1412 and 1414 in this embodiment are substantially the same as those of the steps 1200 to 1208, 1212 and 1214 in the twelfth embodiment.
In step 1410, however, a battery current I B which is one of the quantities indicating the state of loading of the battery 16 is used for judgement in place of the quantity employed in the ninth to thirteenth embodiments, i.e., the required output power for the motor 10 or the quantity associated with the output power of the motor 10. Thus after the execution of the step 1408, the controller 28 judges whether or not the battery current I B lies within the range -a<I B <a (1410). Reference letter a denotes a threshold value for judging whether or not the battery 16 is charged and discharged to a significant degree. The action of the controller 28 advances, if the conditions of the step 1410 are satisfied, to the step 1412, but if not, to the step 1414.
Accordingly this embodiment will ensure the same effects as obtained in the ninth embodiment and allow the state of loading of the battery 16 to be reflected on the control at a higher speed than the ninth embodiment, etc. since the state of loading of the battery 16 is detected for direct use in the control.
d7) Fifteenth Embodiment
Referring to FIG. 20 there is depicted a flow of actions the controller 28 executes for controlling the generated power in the tenth embodiment of the present invention. The actions of steps 1500 to 1508 and 1512 to 1516 in this embodiment are substantially the same as those of the steps 1400 to 1408 and 1412 to 1416 in the fourteenth embodiment. This embodiment differs from the fourteenth embodiment in that the battery current I B is subjected to the moving averaging in step 1510 corresponding to the step 1410, which will enable high-frequency components of the battery current I B to be removed, leading to the realization of a stabler control.
d8) Sixteenth Embodiment
Referring to FIG. 21 there is depicted a flow of actions the controller 28 executes for controlling the generated power in the sixteenth embodiment of the present invention. The actions of steps 1600 to 1608, 1614 and 1616 in this embodiment are respectively the same as those of the steps 1400 to 1408, 1412 and 1414 in the fourteenth embodiment. In this embodiment, however, simultaneously with the execution of the step 1608 the battery currents I B are accumulated (1610) and the object to be judged in the subsequent step 1612 is an accumulated value ΣI B (the quantity of charged and discharged currents) of the battery currents I B . The logic for judgment is substantially the same as that in the fourteenth embodiment. This will allow the high-frequency components of the battery currents I B to be removed, leading to the realization of a stabler control. It is to be noted that this embodiment needs step 1618 for clearing the accumulated value ΣI B .
d9) Seventeenth Embodiment
Referring to FIG. 22 there is depicted a flow of actions the controller 28 executes for controlling the generated power in the seventeenth embodiment of the present invention. The actions of steps 1700 to 1704, 1708, 1710, 1716 and 1718 in this embodiment are substantially the same as those of the steps 1500 to 1508, 1514 and 1516, respectively.
In this embodiment, however, the SOC of the battery 16 is sampled (1706) previous to the step 1708, the SOC of the battery 16 is sampled (1712) previous to the step 1714, and thereafter the sampled value SOC b obtained in the step 1706 is compared with the sampled value SOC obtained in the step 1712 (1714).
Here the SOC of the battery 16 is a value obtained by adding and subtracting the quantity of charged and discharged currents to and from the full capacity of the battery 16 by the controller 28, while on the contrary the quantity of charged and discharged currents are the accumulated value of the battery currents I B as described above. Thus, this embodiment ensures the same effects as obtained in the sixteenth embodiment.
e) Combinations
The above-described embodiments may be combined with one another in a suitable manner.
e1) Eighteenth Embodiment
Referring to FIG. 23 there is depicted the eighteenth embodiment of the present invention comprising a combination of the first embodiment and the twelfth embodiment. As shown, the controller 28 controls the generated power with a predetermined value Z as its target power to be generated (1800). Afterwards the controller 28 resets the variable i to 0 (1802), and samples the instantaneous inverter input power P i (1806) for each of sampling periods Δt (1810). Every execution of the sampling, the controller 28 increments the variable i indicating the number of times of sampling and increases the variable t i by Δt (1804). When the number of times i of sampling reaches a given number of times n (1808), the controller 28 executes steps 1812 to 1818 identical with the steps 110 to 116 in the first embodiment, and then returns to the step 1802. It is to be particularly noted that "5" in the expression (1) associated with the first embodiment is replaced by "n" since the upper limit of the number of times i of sampling is set to n, and that the expression (2) is transformed into t=(3/2) x i x Δt by utilizing the fact that the interval of the timing t i is constant (=Δt).
In the case where the sampled value Pi of the instantaneous inverter input power has changed to a significant degree compared with the current target power (designated at P in the diagram) before reaching n after the number of times of sampling has become 2 or more, in other words, where P-c>P i or P+c <P i has been established (1820; c represents a constant), the controller 28 executes the steps 1812 to 1818 in accordance with i pieces of data sampled by that time, and returns to the step 1802. That is, the decision of the line L and the estimate of the expected inverter input power are intentionally carried out before the execution of n-times sampling. This will allow for any abrupt change in the output power of the motor 10 with accuracy obtained in the first embodiment.
f) Supplement
Although in the first and second embodiments, etc., among the above embodiments the line L is used to approximate the instantaneous inverter input power P i for setting the target power to be generated, the line L may be a curved line, not a straight line.
Although in the second embodiment the approximation line (curved line) L is determined by two timings during a single average period, use may be made of even more timings for that purpose. For instance the following procedure is also naturally available. Several timings are arbitrarily set in the respective vicinities of the two timings so that the instantaneous inverter input power P i is sampled at the individual timings thus set. Thereafter the sampling results are averaged for each of the two timings, and two averages obtained are used to determine the approximation line (it may be a straight line or a curved line) L. This will smooth instantaneous variations of the instantaneous inverter input power P i , contributing to a stabler control.
There may exist three methods in order to find the instantaneous inverter input power P i . First is a method using multiplication of a battery voltage V B and an inverter input current I INV ; second is a method using a multiplication of a motor voltage V M and a motor current I M ; and third is a method using multiplication of a reference torque T ref and the number of rotations N of the motor 10. It will be understood that in the latter two methods the result of the multiplication must be divided by the efficiency of the inverter 20.
Although the accelerator angle θ A is used in some of the above embodiments, the accelerator angle θ A may be substituted by the reference torque T ref . It will be appreciated that use of the externally applied accelerator angle θ A would present an improved responsivity compared with the case using the reference torque T ref obtained after the calculation based on the accelerator angle θ A .
Additionally although in the above embodiments the number of rotations N of the motor 10 is treated as the vehicle velocity v, transmission ratio as well as the number of motor rotations N must be taken into consideration for the vehicles equipped with transmission gears. It is also possible to execute a control focusing on the battery voltage V B instead of the control based on the battery current I B or the SOC.
Furthermore although in the first and second embodiments the approximation line L for a certain averaging period is used to determine the target power to be generated for the next averaging period, this approximation line L may be used to determine the target powers for further subsequent averaging periods.
While the present invention has been described in connection with the preferred embodiments, it is not intended to limit the scope of the invention to the particular forms set forth, but on the contrary, it is intended to cover such alternatives, modifications and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims. | A method of controlling a generated power in a series hybrid vehicle. From the tendency of an inverter input power or a motor dissipation power in a certain period is first estimated the tendency of the inverter input power or the motor dissipation power in the next period. The target power to be generated is then set on the basis of the results of the estimation. Alternatively the target power to be generated is corrected in accordance with the quantities such as an accelerator angle indicating the load of the motor or a battery current indicating the state of charge/discharge of the battery. Alternatively that period is compulsorily interrupted to start the next period. This will eliminate a delay arising from averaging the inverter input powers or the motor dissipation powers for use as the target power in the next period, thus resulting in improved vehicle power efficiency and drive feeling. | 66,478 |
BACKGROUND OF THE INVENTION
[0001] Leishmaniasis is a protozoan parasitic disease endemic in 88 countries, which causes considerable morbidity and mortality. At least 20 species of Leishmania can be transmitted by sandfly bites, originating cutaneous, diffuse cutaneous, mucocutaneous and visceral leishmaniasis in humans, dogs and various wild vertebrate hosts. The estimated yearly incidence is 1-1.5 million cases of cutaneous leishmaniasis and 500,000 cases of visceral leishmaniasis. The population at risk is estimated at 350 million people with an overall prevalence of 12 million. Increasing risk factors are making leishmaniasis a growing public health concern for many countries around the world.
[0002] The drugs most commonly used to treat leishmaniasis are the pentavalent antimonials sodium stibogluconate (Pentostam) and meglumine antimonate (Glucantime). Antimonial chemotherapy requires high dose regimens with long treatment courses using parenteral administration. Second-line drugs, used in instances of antimonial-treatment failure, include amphotericin B (AMB), paromomycin (aminosidine), and pentamidine. However, all of these drugs are far from satisfactory due to unacceptable side effects at effective doses. The recently developed liposomal formulation of amphotericin B (AmBisome™) showed good curative rates for antimony unresponsive cases of mucocutaneous leishmaniasis however, drug administration is technically difficult and treatment costs are prohibitively expensive.
[0003] The spreading resistance of the parasite towards the standby antimonial drugs, the high toxicity of most drugs in use, and the emergence of Leishmania /HIV co-infection as a new disease entity has triggered a continuous search for alternative therapies. Visceral leishmaniasis caused by L. infantum has emerged as an AIDS-associated opportunistic infection, particularly in southern Europe.
[0004] In recent years, alkyllysophospholipid analogues (ALPs) have received considerable interest due to their antineoplastic and immunomodulatory properties. Extensive structure-activity relationship studies on a variety of ALPs showed that a long alkyl chain and a phosphocholine moiety may represent the minimal structural requirements for sufficient antineoplastic effects of ether lipid analogues. This finding led to the synthesis of the alkylphosphocholines (APCs). Within the alkyl chain homologs, hexadecylphosphocholine (HePC) has therapeutically useful antitumor activity and was approved in 1992 as a drug in Germany for the topical treatment of metastasized mammary carcinoma.
[0005] Several in vitro and in vivo studies demonstrated that alkylphosphocholines including HePC, and alkylglycerophosphocholines such as edelfosine, ilmofosine and SRI-62,834 possess antileishmanial activity. Hexadecylphosphocholine was reported to be highly effective in treating mice infected with visceral leishmaniasis while oral treatment with miltefosine was 600-fold more effective than the subcutaneous administration of pentostam. On the basis of these promising observations HePC (miltefosine) was evaluated in phase I and II clinical trials as oral therapy for Indian visceral leishmaniasis while phase III clinical trials are currently ongoing. Cure rates of 88% to 100% were obtained using doses of 100-150 mg/day for 28 days. These results encouraged studies on the efficacy of miltefosine treatment for cutaneous leishmaniasis in the New World and currently phase II studies are being conducted. In a phase I study, the cure rate with miltefosine at doses of 100-150 mg for 3 weeks was 94%. In the various clinical trials, the main side effects associated with miltefosine were gastrointestinal with the most common being moderate vomiting and diarrhea. Transient elevation of transaminases or urea/serum creatinine was noted in a number of patients and decreased under continued treatment. Although the toxicity associated with miltefosine sounds milder than that of some parenteral therapies, gastrointestinal symptoms could be of more consequence in severely ill patients, such as those who are malnourished or dehydrated. In addition, treatment of pregnant women is contraindicated because of miltefosine's teratogenic properties in animals. Furthermore, miltefosine has a very long half-life and low therapeutic ratio and a course of treatment leaves a sub-therapeutic level in the blood for several weeks. These drug characteristics might be expected to encourage development of resistance. Additionally, miltefosine was shown to be only temporarily effective in HIV co-infected patients in Europe. Therefore, a need exists for new phospholipids in the treatment of protozoal diseases and especially leishmaniasis that will not cause significant adverse side effects.
[0006] U.S. Pat. No. 5,436,234 discloses compounds of the general formula:
R—X-A-PO 3 —(CH 2 ) 2 —N + R 1 R 2 R 3
Wherein R is a erucyl, brassidyl or nervonyl radical, R 1 , R 2 and R 3 are, independently of one another, straight-chained, branched or cyclic saturated or unsaturated alkyl radicals containing up to 4 carbon atoms, which can also contain a hydroxyl group, and wherein two of these radicals can also be connected together to form a ring, A is a valency bond or a radical of one of the formulae:
And X is an oxygen atom when A is preferably a valency bond. Compounds of the general formula R-X-A-PO 3 —(CH 2 ) 2 —N + R 1 R 2 R 3 and pharmaceutical compositions containing them can be used for the treatment of protozoal and fungal diseases, autoimmune diseases and bone marrow damage.
[0007] U.S. Pat. No. 6,254,879 which is continuation-in part of application Ser. No. 08/469,779 now U.S. Pat. No. 5,980,915 discloses a new pharmaceutical agent for oral or topical administration in the treatment of protozoal diseases, in particular of leishmaniasis which contains as the active substance one or several compounds of the general formula
R 1 —PO 4 —CH 2 CH 2 —N + R 2 R 3 R 4 ,
in which R 1 is a saturated or monounsaturated or polyunsaturated hydrocarbon residue with 12 to 20 C atoms.
[0008] U.S. Pat. No. 6,344,576 relates to phosphor-lipid compounds of formula (I)
having solubilizing activity for water-insoluble or poorly water soluble active agents and their use in the delivery of active agents to cells and in the treatment of diseases, i.e. cancer and protozoal diseases.
in which A
where R 1 and R 2 are, independently of one another, hydrogen, a saturated or unsaturated acyl or alkyl radical which can optionally be branched or/and substituted, where the total of the carbon atoms in the acyl and alkyl is 16 to 44 C atoms.
SUMMARY OF THE INVENTION
[0009] One aspect of this invention pertains to novel ring containing phospholipids and use thereof in treating protozoal diseases such as leishmaniasis, trypanosomiasis, malaria, toxoplasmosis, babeosis, amoebic dysentery and lambliasis. The compounds of the present invention comprise phospholipids of the general formula A-X—PO 3 —W.
[0010] Another aspect of this invention relates to a method of preparing said compounds.
[0011] A further aspect of this invention relates to method for treating protozoal infections includes administering an effective infection-combating amount of a compound of the present invention in a therapeutic manner.
[0012] A better understanding of the invention will be obtained from the following detailed description of the article and the desired features, properties, characteristics, and the relation of the elements as well as the process steps, one with respect to each of the others, as set forth and exemplified in the description and illustrative embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a graph illustrating the percentage of live THP1 cells in the presence of a different concentrations of some inventive compounds.
[0014] FIG. 2 illustrates some inventive compounds.
[0015] FIG. 3 shows the hemolytic activity of selected examples with respect to miltefosine.
DETAILED DESCRIPTION OF THE INVENTION
[0016] The present invention relates to new ring-containing phospholipids of the general formula A-X—PO 3 —W their stereoisomers and geometrical isomers and physiologically acceptable salts thereof, as well as pharmaceutical compositions containing them.
[0017] The phospholipid compounds of the present invention of general formula A-X—PO 3 —W in the residue A contain rings of different sizes and types at positions of the phospholipid structure which are not encountered in prior art compounds. The prior art compounds bear only straight or branched alkyl chain substituents in the residue A apart from U.S. Pat. No. 5,436,234 in which there is a tetrahydrofuranyl substituent in residue A. However, the prior art compounds are not covered by the formulae of the compounds claimed in the present invention.
[0018] The novel ring-substituted phospholipids of this invention are represented by the general formula A-X—PO 3 —W.
[0019] A comprises a radical selected from one of the formulae Y, YR 1 , R 1 Y, R 1 YR 4 , R 1 OY, YOR 1 , R 1 YOR 2 or R 1 OYOR 2 . Advantageously A comprises YR 1 , R 1 YOR 2 or R 1 OYOR 2
[0020] W comprises a radical of the formulae R 3 Q or a C4 to C7 non-aromatic heterocycle containing a nitrogen heteroatom wherein said heterocycle comprising at least one heteroatom independently selected from nitrogen, oxygen, sulfur and combinations thereof, and wherein said heterocycle can be substituted with one or more substituent groups. Advantageously, the substituent groups are independently selected from hydroxyl, halogen, alkyl, cycloalkyl, aryl, alkoxy, alkoxycarbonyl, alkylthio or amino.
[0021] Y comprises a carbocyclic ring, a carbocyclic ring comprising at least one substituent group, a fused bicyclic ring system, a fused bicyclic ring system comprising at least one substituent group, a bridged bicyclic ring system, a bridged bicyclic ring system comprising at least one substituent group, a bridged tricyclic ring system, a bridged tricyclic ring system comprising at least one substituent group, a heterocyclic ring, a heterocyclic ring comprising at least one substituent group, an aromatic system or an aromatic system comprising at least one substituent group, a heteroaromatic system or a heteroaromatic system comprising at least one substituent group.
[0022] X comprises a valency bond, a methylene group (—CH 2 —) or a heteroatom selected from nitrogen, oxygen, sulfur. Advantageously the heteroatom is an oxygen atom.
[0023] R 1 comprises any possible member selected from a carbocyclic ring having about 3 to about 7 ring members, a heterocyclic ring having about 4 to about 7 ring members, an aromatic ring having about 5 to about 7 ring members, a heteroaromatic ring having about 5 to about 7 ring members, or any above group comprising a substituent group on at least one available ring atom, an about C3 to about C20 saturated or unsaturated, straight or branched, aliphatic hydrocarbon chain, an about C3 to about C20 saturated or unsaturated, straight or branched, aliphatic hydrocarbon chain comprising one or more independently chosen heteroatoms, an about C3 to about C20 saturated or unsaturated, straight or branched, aliphatic hydrocarbon chain comprising at least one independently chosen possible member selected from a carbocyclic ring having about 4 to about 7 ring members, a heterocyclic ring having about 4 to about 7 ring members, an aromatic ring having about 5 to about 7 ring members, a heteroaromatic ring having about 5 to about 7 ring members; or any above member comprising a substituent group on at least one available ring atom, or any above about C3 to about C20 hydrocarbon chain having at least one independently chosen substituent group. Advantageously, the substituent groups for the about C3 to about C20 hydrocarbon chain are independently selected from hydroxyl, halogen, alkyl, cycloalkyl, aryl, alkoxy, alkoxycarbonyl, alkythio or amino.
[0024] R 2 comprises any possible member selected from a carbocyclic ring having about 3 to about 7 ring members, a heterocyclic ring having about 4 to about 7 ring members, an aromatic ring having about 5 to about 7 ring members, a heteroaromatic ring having about 5 to about 7 ring members; any above group comprising a substituent group on at least one available ring atom, an about C2 to about C5 saturated or unsaturated, straight or branched, aliphatic hydrocarbon chain, an about C2 to about C5 saturated or unsaturated, straight or branched, aliphatic hydrocarbon chain comprising one or more independently chosen heteroatoms, an about C2 to about C5 saturated or unsaturated, straight or branched, aliphatic hydrocarbon chain comprising at least one independently chosen possible member selected from a carbocyclic ring having about 4 to about 7 ring members, a heterocyclic ring having about 4 to about 7 ring members, an aromatic ring having about 5 to about 7 ring members, a heteroaromatic ring having about 5 to about 7 ring members; or any above member comprising a substituent group on at least one available ring atom, or any above about C2 to about C5 hydrocarbon chain having at least one independently chosen substituent group.
[0025] Advantageously, R 2 comprises a C2 saturated or unsaturated alkyl or alkenyl, a C2 saturated or unsaturated alkyl or alkenyl which can be substituted with one or more substituents selected from hydroxyl, halogen, alkyl, cycloalkyl, aryl, alkoxy, alkoxycarbonyl, alkylthio and amino.
[0026] R 3 comprises any possible member selected from a carbocyclic ring having about 3 to about 9 ring members, a heterocyclic ring having about 4 to about 9 ring members, an aromatic ring having about 5 to about 9 ring members, a heteroaromatic ring having about 5 to about 9 ring members; any above group comprising a substituent group on at least one available ring atom, an about C2 to about C5 saturated or unsaturated, straight or branched, aliphatic hydrocarbon chain, an about C2 to about C5 saturated or unsaturated, straight or branched, aliphatic hydrocarbon chain comprising one or more independently chosen heteroatoms, an about C2 to about C5 saturated or unsaturated, straight or branched, aliphatic hydrocarbon chain comprising at least one independently chosen possible member selected from a carbocyclic ring having about 4 to about 7 ring members, a heterocyclic ring having about 4 to about 7 ring members, an aromatic ring having about 5 to about 7 ring members, a heteroaromatic ring having about 5 to about 7 ring members; or any above member comprising a substituent group on at least one available ring atom, or any above about C2 to about C5 hydrocarbon chain having at least one independently chosen substituent group.
[0027] Advantageously R 3 comprises a C2 saturated or unsaturated alkyl or alkenyl, a C2 saturated or unsaturated alkyl or alkenyl which can be substituted with one or more substituents selected from hydroxyl, halogen, alkyl, cycloalkyl, aryl, arylalkyl, alkoxy, alkoxycarbonyl, alkylthio and amino or a C3 to C8 cycloalkyl which is bonded at C1 to the oxygen and at C2 to Q.
[0028] R 4 comprises any group independently selected from R 1 or R 2 .
[0029] Q comprises an ammonium group, wherein said ammonium group can be substituted one or more times with a C1 to C6 alkyl radical, or comprises a C3 to C7 heterocycle containing a nitrogen heteroatom which is bonded to the R 3 group, wherein said heterocycle can contain one or more heteroatoms independently selected from nitrogen, oxygen, sulfur and combinations thereof, and wherein said heterocycle can be substituted with one or more substituent groups, a heterobicyclic ring containing a nitrogen heteroatom which is bonded to the R 3 group, wherein said heterobicyclic ring can contain one or more heteroatoms independently selected from nitrogen, oxygen, sulfur and combinations thereof, and wherein said heterobicyclic ring can be substituted with one or more substituent groups, a heterotricyclic ring containing a nitrogen heteroatom which is bonded to the R 3 group, wherein said heterotricyclic ring can contain one or more heteroatoms independently selected from nitrogen, oxygen, sulfur and combinations thereof, and wherein said heterotricyclic ring can be substituted with one or more substituent groups. Advantageously the substituent groups are independently selected from hydroxyl, halogen, alkyl, cycloalkyl, aryl, alkoxy, alkoxycarbonyl, alkylthio or amino.
[0030] Examples of preferred residue R 1 comprise a C5 to C18 alkylidene group or C5 to C18 alkyl group and most preferred pentylidene, undecylidene, dodecylidene, tetradecylidene, and hexadecylidene group or pentyl, undecyl, dodecyl, tetradecyl and hexadecyl groups.
[0031] Examples of preferred Y residue comprise a C3 to C6 carbocyclic ring, a substituted carbocyclic ring, a bridged tricyclic ring system or a substituted bridged tricyclic ring system an aromatic ring and most preferred are cyclohexyl or adamantyl or phenyl. A C2 saturated alkyl is most preferred for R 2 and R 3 . Oxygen is preferred for X. Trimethylammonium, or N-methylmorpholinio or N-methylpiperidinio is most preferred for Q.
[0032] The inventive compounds include any and all isomers and steroisomers, as well as their addition salts, particularly their pharmaceutically acceptable addition salts. In general, the compositions of the invention may be alternately formulated to comprise, consist of, or consist essentially of, any appropriate components herein disclosed. The compositions of the invention may additionally, or alternatively, be formulated so as to be devoid, or substantially free, of any components, materials, ingredients, adjuvants or species used in prior art compositions or that are otherwise not necessary to the achievement of the function and/or objectives of the present invention.
[0033] Unless otherwise specifically defined, “acyl” refers to the general formula —C(O)alkyl.
[0034] Unless otherwise specifically defined, “acyloxy” refers to the general formula —O-acyl.
[0035] Unless otherwise specifically defined, “alcohol” refers to the general formula alkyl-OH and includes primary, secondary and tertiary variations.
[0036] Unless otherwise specifically defined, “alkyl” or “lower alkyl” refers to a linear, branched or cyclic alkyl group having from 1 to about 16 carbon atoms including, for example, methyl, ethyl, propyl, butyl, hexyl, octyl, isopropyl, isobutyl, tert-butyl, cyclopropyl, cyclohexyl, cyclooctyl, vinyl and allyl. The alkyl group can be saturated or unsaturated. Unless otherwise specifically limited, an alkyl group can be unsubstituted, singly substituted or, if possible, multiply substituted, with substituent groups in any possible position. Unless otherwise specifically limited, a cyclic alkyl group includes monocyclic, bicyclic, tricyclic and polycyclic rings, for example norbornyl, adamantyl and related terpenes.
[0037] Unless otherwise specifically defined, “alkoxy” refers to the general formula —O-alkyl.
[0038] Unless otherwise specifically defined, “alkylmercapto” refers to the general formula —S-alkyl.
[0039] Unless otherwise specifically defined, “alkylamino” refers to the general formula —(NH)-alkyl.
[0040] Unless otherwise specifically defined, “di-alkylamino” refers to the general formula —N(alkyl) 2 . Unless otherwise specifically limited di-alkylamino includes cyclic amine compounds such as piperidine and morpholine.
[0041] Unless otherwise specifically defined, an aromatic ring is an unsaturated ring structure having about 5 to about 7 ring members and including only carbon as ring atoms. The aromatic ring structure can be unsubstituted, singly substituted or, if possible, multiply substituted, with substituent groups in any possible position.
[0042] Unless otherwise specifically defined, “aryl” refers to an aromatic ring system that includes only carbon as ring atoms, for example phenyl, biphenyl or naphthyl. The aryl group can be unsubstituted, singly substituted or, if possible, multiply substituted, with substituent groups in any possible position.
[0043] Unless otherwise specifically defined, “aroyl” refers to the general formula —C(═O)-aryl.
[0044] Unless otherwise specifically defined, a bicyclic ring structure comprises 2 fused or bridged rings that include only carbon as ring atoms. The bicyclic ring structure can be saturated or unsaturated. The bicyclic ring structure can be unsubstituted, singly substituted or, if possible, multiply substituted, with substituent groups in any possible position. The individual rings may or may not be of the same type. Examples of bicyclic ring structures include, Dimethyl-bicyclo[3,1,1]heptane, bicyclo[2,2,1]heptadiene, decahydro-naphthalene and bicyclooctane.
[0045] Unless otherwise specifically defined, a carbocyclic ring is a non-aromatic ring structure, saturated or unsaturated, having about 3 to about 8 ring members that includes only carbon as ring atoms, for example, cyclohexadiene or cyclohexane. The carbocyclic ring can be substituted, singly substituted or, if possible, multiply substituted, with substituent groups in any possible position.
[0046] Unless otherwise specifically defined, “halogen” refers to an atom selected from fluorine, chlorine, bromine and iodine.
[0047] Unless otherwise specifically defined, a heteroaromatic ring is an unsaturated ring structure having about 5 to about 8 ring members that has carbon atoms and one or more heteroatoms, including oxygen, nitrogen and/or sulfur, as ring atoms, for example, pyridine, furan, quinoline, and their derivatives. The heteroaromatic ring can be unsubstituted, singly substituted or, if possible, multiply substituted, with substituent groups in any possible position.
[0048] Unless otherwise specifically defined, a heterobicyclic ring structure comprises 2 fused or bridged rings that include carbon and one or more heteroatoms, including oxygen, nitrogen and/or sulfur, as ring atoms. The heterobicyclic ring structure is saturated or unsaturated. The heterobicyclic ring can be unsubstituted, singly substituted or, if possible, multiply substituted, with substituent groups in any possible position. The individual rings may or may not be of the same type. Examples of heterobicyclic ring structures include tropane, quinuclidine and tetrahydro-benzofuran.
[0049] Unless otherwise specifically defined, a heterocyclic ring is a saturated or unsaturated ring structure having about 3 to about 8 ring members that has carbon atoms and one or more heteroatoms, including oxygen, nitrogen and/or sulfur, as ring atoms, for example, piperidine, morpholine, piperazine, pyrrolidine, thiomorpholine, tetrahydropyridine, and their derivatives. The heterocyclic ring can be unsubstituted, singly substituted or, if possible, multiply substituted, with substituent groups in any possible position.
[0050] Unless otherwise specifically defined, a heterotricyclic ring structure comprises 3 rings that may be fused, bridged or both fused and bridged, and that include carbon and one or more heteroatoms, including oxygen, nitrogen and/or sulfur, as ring atoms. The heterotricyclic ring structure can be saturated or unsaturated. The heterotricyclic ring structure can be unsubstituted, singly substituted or, if possible, multiply substituted, with substituent groups in any possible position. The individual rings may or may not be of the same type. Examples of heterotricyclic ring structures include 2,4,10-trioxaadamantane, tetradecahydro-phenanthroline.
[0051] Unless otherwise specifically defined, a heteropolycyclic ring structure comprises more than 3 rings that may be fused, bridged or both fused and that include carbon and one or more heteroatoms, including oxygen, nitrogen and/or sulfur, as ring atoms. The heteropolycyclic ring structure can be saturated or unsaturated. The heteropolycyclic ring structure can be unsubstituted, singly substituted or, if possible, multiply substituted, with substituent groups in any possible position. The individual rings may or may not be of the same type. Examples of heteropolycyclic ring structures include azaadamantine, 5-norbornene-2,3-dicarboximide.
[0052] Unless otherwise specifically defined, the term “phenacyl” refers to the general formula -phenyl-acyl.
[0053] Unless otherwise specifically defined, a polycyclic ring structure comprises more than 3 rings that may be fused, bridged or both fused and bridged, and that includes carbon as ring atoms. The polycyclic ring structure can be saturated or unsaturated. The polycyclic ring structure can be unsubstituted, singly substituted or, if possible, multiply substituted, with substituent groups in any possible position. The individual rings may or may not be of the same type. Examples of polycyclic ring structures include adamantine, bicyclooctane, norbornane and bicyclononanes.
[0054] Unless otherwise specifically defined, a spirocycle refers to a ring system wherein a single atom is the only common member of two rings. A spirocycle can comprise a saturated carbocyclic ring comprising about 3 to about 8 ring members, a heterocyclic ring comprising about 3 to about 8 ring atoms wherein up to about 3 ring atoms may be N, S, or O or a combination thereof.
[0055] Unless otherwise specifically defined, a tricyclic ring structure comprises 3 rings that may be fused, bridged or both fused and bridged, and that includes carbon as ring atoms. The tricyclic ring structure can be saturated or unsaturated. The tricyclic ring structure can be unsubstituted, singly substituted or, if possible, multiply substituted, with substituent groups in any possible position and may be substituted or unsubstituted. The individual rings may or may not be of the same type. Examples of tricyclic ring structures include fluorene and anthracene.
[0056] Unless otherwise specifically limited the term substituted means substituted by a below described substituent group in any possible position. Substituent groups for the above moieties useful in the invention are those groups that do not significantly diminish the biological activity of the inventive compound. Substituent groups that do not significantly diminish the biological activity of the inventive compound include, for example, H, halogen, N 3 , NCS, CN, NO 2 , NX 1 X 2 , OX 3 , OAc, O-acyl, O-aroyl, OalkylOH, OalkylNX 1 X 2 , NH-acyl, NH-aroyl, NHCOalkyl, CHO, CF 3 , COOX 3 , SO 3 H, PO 3 X 1 X 2 , OPO 3 X 1 X 2 , SO 2 NX 1 X 2 , CONX 1 X 2 , alkyl, alcohol, alkoxy, alkylmercapto, alkylamino, di-alkylamino, sulfonamide, thioalkoxy, aryl, substituted aryl, heteroaryl, substituted heteroaryl or methylene dioxy when the substituted structure has two adjacent carbon atoms, wherein X 1 and X 2 each independently comprise H or alkyl, or X 1 and X 2 together comprise part of a heterocyclic ring having about 4 to about 7 ring members and optionally one additional heteroatom selected from O, N or S, or X 1 and X 2 together comprise part of an imide ring having about 5 to about 6 members and X 3 comprises H, alkyl, hydroxyloweralkyl, or alkyl-NX 1 X 2 . Unless otherwise specifically limited a substituent group may be in any possible position.
[0057] The present invention also pertains to methods for treating protozoal diseases such as leishmaniasis, trypanosomiasis, malaria, toxoplasmosis, babeosis, amoebic dysentery and lambliasis. The method comprises administering an effective infection-combating amount of a compound of the present invention in a therapeutic manner. In one embodiment, an effective dose includes a sufficient amount of one stereoisomer or mixture of stereoisomers where all stereoisomers of said compound possess antiprotozoal properties. In an alternate embodiment, where only one stereoisomer of a compound possesses significant antiprotozoal properties an effective dose comprises a sufficient amount of the pure antiprotozoal stereoisomer.
[0058] The compounds of the present invention can be administered topically, enterally and parenterally in liquid or solid form.
[0059] The invention further relates to a method of preparing said compounds. According to the invention the compounds of formula A-X—PO 3 —W are synthesized in the following way:
[0060] i) Treating the appropriate alcohol A-OH in which A is defined above with phosphorus oxychloride in an organic solvent such as tetrahydrofuran for example in the presence of an organic base, such as triethylamine for example to afford the corresponding phosphoric acid derivative after hydrolysis.
[0061] ii) Treating the phosphoric acid said above with 1-(mesitylen-2-sulfonyl)-3-nitro-1H-1,2,4-triazole or 2,4,6-triisopropylbenzenesulfonyl chloride in an organic base, such as pyridine for example followed by the addition of the appropriate alcohol W—OH in which W is defined above and heating the resulting mixture to provide after hydrolysis the phospholipid A-X—PO 3 —W.
[0062] The invention will be further illustrated by the following non-limiting examples.
EXEMPLIFICATION
Synthetic Procedures
[0000] General Methods
[0063] All reactions were carried out under scrupulously dry conditions. NMR spectra of all new compounds were recorded on a Bruker AC 300 spectrometer operating at 300 MHz for 1 H, 75.43 MHz for 13 C, and 121.44 MHz for 31 P. 1 H NMR spectra are reported in units 6 with CHCl 3 resonance at 7.24 ppm used as the chemical shift resonance. 13 C NMR shifts are expressed in units relative to CDCl 3 at 77.00 ppm, while 31 P NMR spectra are reported in units of δ relative to 85% H 3 PO 4 used as an external standard. Silica gel plates Merck F 254 ) were used for thin-layer chromatography. Chromatographic purification was performed with silica gel (200-400 mesh).
[0000] General Procedure for the Preparation of Ether Phospholipids.
[0064] To a solution of phosphorus oxychloride (0.09 mL, 1 mmol) and triethylamine (0.25 mL, 1.8 mmol) in dry THF (5 mL) was added dropwise at 0° C. a solution of the corresponding alcohol (1 mmol) in dry THF (7 mL). The resulting mixture was stirred for 2 h at room temperature and subsequently hydrolyzed by the addition of water (3 mL). After 1 h of stirring at room temperature, the reaction mixture was diluted with water and the aqueous layer was extracted with ethyl acetate and dichloromethane. The combined organic extracts were washed with brine, dried with anhydrous Na 2 SO 4 and the solvent was evaporated in vacuo to afford the corresponding phosphoric acid derivative, which was transformed to the pyridinium salt by the addition of 7 mL of anhydrous pyridine and stirring for 2 h at 40° C. After cooling the solvent was evaporated in vacuo and pyridine (5 mL) was added to the residue. To the resulting solution was added dropwise with cooling, a solution of 1-(mesitylen-2-sulfonyl)-3-nitro-1H-1,2,4-triazole (MSNT) (0.593 g, 2 mmol) or 2,4,6-triisopropylbenzenesulfonyl chloride (TIPS-Cl) (0.606 g, 2 mmol) in dry pyridine (2 mL) followed by the addition of choline chloride (0.210 g, 1.5 mmol) or N-(2-hydroxyethyl)-N-methylpiperidinium bromide (0.448 g, 1.5 mmol) or N-(2-hydroxyethyl)-N-methylmorpholinium bromide (0.452 g, 1.5 mmol). The reaction mixture was stirred at 40° C. for 48-56 hours. After cooling, the mixture was hydrolyzed by the addition of H 2 O (2 mL) and 2-propanol (7 mL) and stirred for 1 h at room temperature. The solvents were evaporated in vacuo and the resulting crude solid was purified by gravity column chromatography using initially CH 2 Cl 2 /MeOH/25% NH 4 OH (60/50/5) and subsequently MeOH/25% NH 4 OH (95/5) and the solvents were evaporated in vacuo. The residue was diluted with CHCl 3 and filtered through a pore membrane (0.5 μM, FH Millipore). After evaporation of the solvent the desired product was obtained.
Example 1
1-{2-{[(4-Dodecylidenecyclohexyloxy)ethyloxy]hydroxyphosphinyloxy}ethyl}-N,N,N-trimethylammonium inner salt
[0065] The general procedure described above using 2-(4-dodecylidenecyclohexyloxy)ethanol, TIPS-Cl and choline chloride afforded the compound named above (0.327 g, 69%). 1 H NMR: δ 5.06 (t, J=6.7 Hz, 1H, C═CH), 4.24 (broad s, 2H, POCH 2 CH 2 N), 3.89 (broad s, 2H), 3.76 (broad s, 2H), 3.57 (broad s, 2H), 3.40-3.35 (m, 1H, CHO), 3.30 (s, 9H, N + (CH 3 ) 3 ), 2.40-1.72 (m, 8H), 1.42-1.33 (m, 2H), 1.24 (broad s, 18H, (CH 2 ) 9 ), 0.84 (t, J=7.0 Hz, 3H, CH 3 ); 31 P NMR: δ −2.16.
Example 2
1-{2-{[(4-Dodecylidenecyclohexyloxy)ethyloxy]hydroxyphosphinyloxy}ethyl}-1-methylpiperidinium inner salt
[0066] The general procedure described above using 2-(4-dodecylidenecyclohexyloxy)ethanol, TIPS-Cl and N-(2-hydroxyethyl)-N-methylpiperidinium bromide afforded the compound named above (0.350 g, 68%). 1 H NMR δ: 5.16 (t, J=6.70 Hz, 1H, C═CH), 4.24 (bs, 2H, POCH 2 CH 2 N), 3.82-3.55 (m, 10H), 3.30 (broad s, 1H, CHO), 3.25 (s, 3H, N + CH 3 ), 1.92-1.43 (m, 14H), 1.41-1.32 (m, 2H, CH 2 CH═), 1.19 (broad s, 18H, (CH 2 ) 9 ), 0.83 (t, J=7.0 Hz, 3H, CH 3 ); 31 P NMR δ: −2.1.
Example 3
1-{2-{[(4-Dodecylidenecyclohexyloxy)ethyloxy]hydroxyphosphinyloxy}ethyl}-1-methylmorpholinium inner salt
[0067] The general procedure described above using 2-(4-dodecylidenecyclohexyloxy) ethanol, TIPS-Cl and N-(2-hydroxyethyl)-N-methylmorpholinium bromide afforded the compound named above (0.330 g, 64%). 1 H NMR: δ 5.11 (t, J=6.7 Hz, 1H, C═CH), 4.13 (s, 2H, POCH 2 CH 2 N), 3.82-3.32 (m, 15H), 3.16 (s, 3H, N + CH 3 ), 1.92-1.47 (m, 8H), 1.42-1.34 (m, 2H, CH 2 CH═), 1.27 (broad s, 18H, (CH 2 ) 9 ), 0.83 (t, J=7.0 Hz, 3H, CH 3 ); 31 P NMR δ: −2.04.
Example 4
1-{2-{1[(4-Tetradecylidenecyclohexyloxy)ethyloxy]hydroxyphosphinyloxy}ethyl}-N,N,N-trimethylammonium inner salt
[0068] The general procedure described above using 2-(4-tetradecylidenecyclohexyloxy)ethanol, TIPS-Cl and choline chloride afforded the compound named above (0.166 g, 33%). 1 H NMR: δ 5.05 (t, J=6.7 Hz, 1H, CH═C), 4.23 (broad s, 2H, POCH 2 CH 2 N), 3.88 (broad s, 2H), 3.75 (broad s, 2H), 3.55 (broad s, 2H, CH 2 N), 3.40-3.35 (m, 1H, CHO), 3.32 (s, 9H, N + (CH 3 ) 3 ), 2.41-2.37 (m, 1H), 2.17-2.13 (m, 1H), 1.89-1.74 (m, 8H), 1.21 (broad s, 22H, (CH 2 ) 11 ), 0.89 (t, J=7.0 Hz, 3H, CH 3 ); 31 P NMR: δ −2.26; 13 C NMR: δ 136.9, 122.7, 74.3, 67.7, 64.7, 54.2, 33.4, 32.5, 31.9, 30.1, 29.6, 29.3, 27.4, 24.9, 22.6, 14.0.
Example 5
1-{2-{[(4-Tetradecylidenecyclohexyloxy)ethyloxy]hydroxyphosphinyloxy}ethyl}-1-methylpiperidinium inner salt
[0069] The general procedure described above using 2-(4-tetradecylidenecyclohexyloxy) ethanol, TIPS-Cl and N-(2-hydroxyethyl)-N-methylpiperidinium bromide afforded the compound named above (0.201 g, 37%). 1 H NMR: δ 5.21 (t, J=6.7 Hz, 1H, CH═C), 4.31 (bs, 2H, POCH 2 CH 2 N), 3.93-3.80 (m, 4H), 3.60-3.43 (m, 6H, CH 2 N(CH 2 ) 2 ), 3.30 (broad s, 4H, NCH 3 , CHO), 2.40-1.40 (m, 16H), 1.23 (broad s, 22H, (CH 2 ) 11 ), 0.88 (t, J=7.0 Hz, 3H, CH 3 ); 31 P NMR: δ −2.4.
Example 6
1-{2-{[(4-Tetradecylidenecyclohexyloxy)ethyloxy]hydroxyphosphinyloxy}ethyl}-1-methylmorpholinium inner salt
[0070] The general procedure described above using 2-(4-tetradecylidenecyclohexyloxy) ethanol, TIPS-Cl and N-(2-hydroxyethyl)-N-methylmorpholinium bromide afforded the compound named above (0.218 g, 40%). 1 H NMR: δ 5.06 (t, J=6.7 Hz, 1H, CH═C), 4.07 (broad s, 2H, POCH 2 CH 2 N), 3.49-3.17 (m, 5H), 3.11 (s, 3H, N + CH 3 ), 1.99-1.34 (m, 10H), 1.08 (broad s, 22H, (CH 2 ) 11 ), 0.78 (t, J=7.0 Hz, 3H, CH 3 ); 31 P NMR: δ −1.9.
Example 7
1-{2-{[(4-Hexadecylidenecyclohexyloxy)ethyloxy]hydroxyphosphinyloxy}ethyl}-N,N,N-trimethylammonium inner salt
[0071] The general procedure described above using 2-(4-hexadecylidenecyclohexyloxy) ethanol, TIPS-Cl and choline chloride afforded the compound named above (0.196 g, 37%). 1 H NMR: δ 5.08 (t, J=6.7 Hz, 1H, CH═C), 4.09 (broad s, 2H, OP(O)CH 2 CH 2 N), 3.82 (broad s, 2H, OCH 2 CH 2 OP), 3.71 (broad s, 2H, OCH 2 CH 2 OP), 3.51-3.43 (m, 2H, CH 2 N), 3.04 (s, 10H, CHO, N + (CH 3 ) 3 ), 2.45-2.40 (m, 1H), 2.25-2.20 (m, 1H), 2.02-1.85 (m, 6H), 1.51-1.42 (m, 2H, CH 2 CH═), 1.09 (broad s, 26H, (CH 2 ) 13 ), 0.71 (t, J=7.0 Hz, 3H, CH 3 ); 31 P NMR: δ −2.04.
Example 8
1-{2-{[(4-Hexadecylidenecyclohexyloxy)ethyloxy]hydroxyphosphinyloxy}ethyl}-1-methylpiperidinium inner salt
[0072] The general procedure described above using 2-(4-hexadecylidenecyclohexyloxy) ethanol, TIPS-Cl and N-(2-hydroxyethyl)-N-methylpiperidinium bromide afforded the compound named above (0.211 g, 37%). 1 H NMR: δ 5.13 (t, J=6.7 Hz, 1H, CH═C), 4.35 (broad s, 2H, POCH 2 ), 3.87 (broad s, 2H), 3.78 (broad s, 2H), 3.62-3.45 (m, 6H), 3.26 (broad s, 4H), 2.27-1.63 (m, 8H), 1.52-1.41 (m, 2H, CH 2 CH═), 1.24 (broad s, 26H, (CH 2 ) 13 ), 0.89 (t, J=7.0 Hz, 3H, CH 3 ); 31 P NMR: δ −2.0; 13 C NMR: δ 138.0, 117.4, 75.1, 67.8, 67.7, 64.8, 63.3, 61.8, 58.7, 48.8, 37.2, 31.8, 30.1, 29.7, 29.6, 29.4, 29.3, 28.4, 27.7, 27.2, 22.5, 20.9, 20.1, 14.0.
Example 9
1-{2-{[(4-Hexadecylidenecyclohexyloxy)ethyloxy]hydroxyphosphinyloxy}ethyl}-1-methylmorpholinium inner salt
[0073] The general procedure described above using 2-(4-hexadecylidenecyclohexyloxy) ethanol, TIPS-Cl and N-(2-hydroxyethyl)-N-methylmorpholinium bromide afforded the compound named above (0.206 g, 36%). 1 H NMR: δ 5.06 (t, J=6.70 Hz, 1H, CH═C), 4.41 (bs, 2H, POCH 2 ), 3.99-3.39 (m, 15H), 3.35 (s, 3H, N + CH 3 ), 2.45-2.40 (m, 1H, CHCHOCH 2 ), 2.25-2.20 (m, 1H, CH 2 CHOCH), 2.13-1.85 (m, 6H), 1.22 (broad s, 28H, (CH 2 ) 14 ), 0.89 (t, J=7.0 Hz, 3H, CH 3 ); 31 P NMR: δ −2.17; 13 C NMR: δ 136.8, 122.8, 65.3, 60.7, 33.4, 33.3, 32.4, 31.8, 30.1, 29.6, 29.4, 29.3, 27.4, 24.9, 22.6, 14.0.
Example 10
1-{2-[(5-Cyclohexylidenepentyloxy)hydroxyphosphinyloxy]ethyl}-N,N,N-trimethylammonium inner salt
[0074] The general procedure described above using 5-cyclohexylidenepentanol, MSNT and choline chloride afforded the compound named above (0.219 g, 66%); 1 H NMR: δ 4.99 (t, J=6.7 Hz, 1H, C═CH), 4.21 (broad s, 2H, POCH 2 CH 2 N), 3.74 (broad s, 4H, CH 2 OPOCH 2 CH 2 N), 3.34 (s, 9H, N + (CH 3 ) 3 ), 2.09-1.84 (m, 6H), 1.55-1.28 (m, 10H); 31 P NMR: δ −2.16; 13 C NMR: δ 139.8, 120.8, 66.1, 65.4, 59.1, 54.2, 37.1, 30.6, 28.6, 27.8, 26.9, 26.4, 25.6; ESI-MS m/z: 356.2 (M + +Na + ), 334.2 (M + ).
Example 11
1-{2-[(5-Cyclohexyldenepentyloxy)hydroxyphosphinyloxy]ethyl}-1-methylpiperidinium inner salt
[0075] The general procedure described above using 5-cyclohexylidenepentanol, MSNT and N-(2-hydroxyethyl)-N-methylpiperidinium bromide afforded the compound named above (0.153 g, 41%); 1 H NMR: δ 5.02 (t, J=6.7 Hz, 1H, C═CH), 4.28 (broad s, 2H, POCH 2 CH 2 N), 3.82-3.42 (m, 8×, CH 2 OPOCH 2 CH 2 N(CH 2 ) 2 ), 3.31 (s, 3H, N + CH 3 ), 2.08-1.48 (m, 16H), 1.23 (broad s, 6H, (CH 2 ) 3 ); 31 P NMR: δ −2.04; ESI-MS m/z: 374.2 (M + ).
Example 12
1-{2-[(5-Cyclohexylidenepentyloxy)hydroxyphosphinyloxy]ethyl}-1-methylmorpholinium inner salt
[0076] The general procedure described above using 5-cyclohexylidenepentanol, MSNT and N-(2-hydroxyethyl)-N-methylmorpholinium bromide afforded the compound named above (0.153 g, 41%). 1 H NMR: δ 5.01 (t, J=6.7 Hz, 1H, C═CH), 4.29 (broad s, 2H, POCH 2 CH 2 N), 4.11-3.68 (m, 12H), 3.42 (s, 3H, N + CH 3 ), 2.09-1.95 (m, 4H), 1.58-1.49 (m, 6H), 1.31 (broad s, 6H, (CH 2 ) 3 ); 31 P NMR: δ −2.23; ESI-MS m/z: 376.2 (M + ).
Example 13
1-{2-[(11-Cyclohexylideneundecyloxy)hydroxyphosphinyloxy]ethyl}-N,N,N-trimethylammonium inner salt
[0077] The general procedure described above using 11-cyclohexylideneundecanol, MSNT and choline chloride afforded the compound named above (0.220 g, 52%). 1 H NMR δ: 5.05 (t, J=6.7 Hz, 1H, C═CH), 4.20 (broad s, 2H, POCH 2 CH 2 N), 3.75-3.68 (m, 4H, CH 2 OPOCH 2 CH 2 N), 3.26 (s, 9H, N + (CH 3 ) 3 ), 2.11-1.92 (m, 4H), 1.65-1.48 (1,6H), 1.23 (broad s, 18H, (CH 2 ) 9 ); 31 P NMR: δ −2.45; 13 C NMR: δ 131.0, 124.8, 66.1, 66.0, 59.1, 54.1, 31.0, 30.2, 29.9, 29.7, 29.6, 29.5, 29.3, 28.6, 28.0, 27.8, 27.0, 26.9, 25.9, 25.7; ESI-MS m/z: 440.2 (M + +Na + ), 418.2 (M + ).
Example 14
1-{2-[(11-Cyclohexylideneundecyloxy)hydroxyphosphinyloxy]ethyl}-1-methylpiperidinium inner salt
[0078] The general procedure described above using 11-cyclohexylideneundecanol, MSNT and N-(2-hydroxyethyl)-N-methylpiperidinium bromide afforded the compound named above (0.315 g, 69%). 1 H NMR: δ 4.99 (t, J=6.7 Hz, 1H, C═CH), 4.23 (bs, 2H, POCH 2 CH 2 N), 3.78-3.48 (m, 8H, CH 2 OPOCH 2 CH 2 N(CH 2 ) 2 ), 3.27 (s, 3H, N + CH 3 ), 2.04-1.45 (m, 16H), 1.18 (broad s, 18H, (CH 2 ) 9 ); 31 P NMR δ: −2.04; 13 C NMR: δ 130.9, 124.7, 65.3, 63.2, 58.4, 48.5, 37.0, 31.0, 30.9, 30.1, 29.8, 29.6, 29.5, 29.4, 29.2, 28.6, 27.9, 27.7, 26.8, 25.8, 25.6; ESI-MS m/z: 480.3 (M + +Na + ), 458.3 (M + ).
Example 15
1-{2-[(11-Cyclohexylideneundecyloxy)hydroxyphosphinyloxy]ethyl}-1-methylmorpholinium inner salt
[0079] The general procedure described above using 11-cyclohexylideneundecanol, MSNT and N-(2-hydroxyethyl)-N-methylmorpholinium bromide afforded the compound named above (0.117 g, 25%). 1 H NMR: δ 5.05 (t, J=6.7 Hz, 1H, C═CH), 4.29 (broad s, 2H, POCH 2 CH 2 N), 3.99-3.70 (m, 12H), 3.48 (s, 3H, N + CH 3 ), 2.08-1.92 (m, 4H), 1.65-1.48 (m, 6H), 1.23 (s, 18H, (CH 2 ) 9 ); 31 P NMR: 6-2.13; 13 C NMR: δ 131.0, 124.8, 65.8, 64.3, 60.7, 58.5, 48.3, 37.1, 31.0, 30.9, 29.9, 29.7, 29.6, 29.5, 29.4, 29.3, 28.6, 28.2, 28.0, 27.8, 27.0, 25.8, 25.7, 17.6.
Example 16
1-{2-[(5-Adamantylidenepentyloxy)hydroxyphosphinyloxy]ethyl}-N,N,N-trimethylammonium inner salt
[0080] The general procedure described above using 5-adamantylidenepentanol, MSNT and choline chloride afforded the compound named above (0.223 g, 58%). 1 H NMR: δ 4.96 (t, J=6.7 Hz, 1H, C═CH), 4.22 (broad s, 2H, POCH 2 CH 2 N), 3.77-3.71 (m, 4H, CH 2 OPOCH 2 CH 2 N), 3.29 (s, 9H, N + (CH 3 ) 3 ), 2.75 (s, 1H, CHC═), 2.27 (s, 1H, CHC═), 1.95-1.53 (m, 161), 1.34-1.29 (m, 2H); 31 P NMR: δ −2.42; 13 C NMR: δ 147.7, 115.9, 66.3, 65.5, 59.1, 54.3, 40.5, 39.8, 38.9, 37.2, 32.0, 30.6, 28.6, 26.6, 26.2; ESI-MS m/z: 408.1 (M + +Na + ), 386.1 (M + ).
Example 17
1-(2-[(5-Adamantlidenepentloxy)hydroxyphosphinyloxy]ethyl)-1-methylpiperidinium inner salt
[0081] The general procedure described above using 5-adamantylidenepentanol, MSNT and N-(2-hydroxyethyl)-N-methylpiperidinium bromide afforded the compound named above (0.272 g, 64%). 1 H NMR δ: 4.93 (t, J=6.7 Hz, 1H, C═CH), 4.25 (broad s, 2H, POCH 2 CH 2 N), 3.79-3.60 (m, 8H, CH 2 OPOCH 2 CH 2 N(CH 2 ) 2 ), 3.32 (s, 3H, N + (CH 3 ) 3 ), 2.72 (s, 1H, CHC═), 2.24 (s, 1H, CHC═), 1.92-1.50 (m, 22H), 1.31-1.26 (m, 2H); 31 P NMR: δ −1.9; 13 C NMR: δ 147.6, 115.9, 65.4, 65.3, 63.5, 58.6, 58.5, 48.6, 40.5, 39.8, 38.9, 37.2, 32.0, 30.7, 30.6, 28.6, 26.6, 26.2, 20.9, 20.2; ESI-MS m/z: 448.2 (M + +Na + ), 426.2 (M + ).
Example 18
1-{2-[(5-Adamantylidenepentyloxy)hydroxyphosphinyloxy]ethyl}-1-methylmorpholinium inner salt
[0082] The general procedure described above using 5-adamantylidenepentanol, MSNT and N-(2-hydroxyethyl)-N-methylmorpholinium bromide afforded the compound named above (0.239 g, 56%). 1 H NMR δ: 4.94 (t, J=6.7 Hz, 1H, C═CH), 4.27 (broad s, 2H, POCH 2 CH 2 N), 3.99-3.69 (m, 12H), 3.43 (s, 3H, N + CH 3 ), 2.73 (s, 1H, CHC═), 2.25 (s, 1H, CHC═), 1.96-1.32 (m, 16H), 1.29-1.18 (m, 2H); 31 P NMR: δ −2.16; 13 C NMR: δ 147.8, 115.8, 65.6, 65.5, 64.3, 60.7, 58.5, 48.3, 40.5, 39.8, 38.9, 37.2, 32.0, 30.6, 30.5, 28.6, 26.6, 26.5; ESI-MS m/z: 450.2 (M + +Na + ), 428.2 (M + ).
Example 19
1-{2-[(11-Adamantylideneundecyloxy)hydroxyphosphinyloxy]ethyl}-N,N,N-trimethylammonium inner salt
[0083] The general procedure described above using 11-adamantylideneundecanol, MSNT and choline chloride afforded the compound named above (0.248 g, 53%). 1 H NMR: δ 4.98 (t, J=6.7 Hz, 1H, C═CH), 4.21 (broad s, 2H, POCH 2 CH 2 N), 3.75 (broad s, 4H, CH 2 OPOCH 2 CH 2 N), 3.32 (s, 9H, N + (CH 3 ) 3 ), 2.77 (s, 1H, CHC═), 2.28 (s, 1H, CHC═), 1.91-1.53 (m, 16H), 1.23 (broad s, 14H); 31 P NMR: δ −2.16; 13 C NMR: δ: 147.2, 116.3, 66.1, 65.5, 59.2, 54.2, 40.5, 39.8, 38.9, 37.3, 32.0, 31.0, 30.9, 29.7, 29.6, 29.5, 29.2, 28.7, 26.5, 25.9; ESI-MS m/z: 492.2 (M + +Na + ), 470.2 (M + ).
Example 20
1-{2-[(11-Adamantylideneundecyloxy)hydroxyphosphinyloxy]ethyl}-1-methylpiperidinium inner salt
[0084] The general procedure described above using 11-adamantylideneundecanol, MSNT and N-(2-hydroxyethyl)-N-methylpiperidinium bromide afforded the compound named above (0.168 g, 33%). 1 H NMR δ: 4.98 (t, J=6.7 Hz, 1H, C═CH), 4.27 (broad s, 2H, POCH 2 CH 2 N), 3.84-3.52 (m, 8H, CH 2 OPOCH 2 CH 2 N(CH 2 ) 2 ), 3.32 (s, 3H, NCH 3 ), 2.76 (s, 1H, CHC═), 2.27 (s, 1H, CHC═), 1.92-1.53 (m, 22H), 1.23 (broad s, 14H); 31 P NMR: δ−2.04; 13 C NMR: δ 147.2, 116.3, 65.1, 62.1, 57.3, 47.4, 40.5, 39.9, 38.9, 37.5, 32.0, 30.3, 29.6, 29.5, 29.4, 29.2, 28.7, 26.4, 25.8, 20.9, 20.2; ESI-MS m/z: 532.3 (M + +Na + ), 510.3 (M + ).
Example 21
1-{2-[(11-Adamantylideneundecyloxy)hydroxyphosphinyloxy]ethyl}-1-methylmorpholinium inner salt
[0085] The general procedure described above using 11-adamantylideneundecanol, MSNT and N-(2-hydroxyethyl)-N-methylmorpholinium bromide afforded the compound named above (0.235 mg, 46%). 1 H NMR: δ 4.99 (t, J=6.7 Hz, 1H, C═CH), 4.29 (broad s, 2H, POCH 2 CH 2 N), 4.00-3.67 (m, 12H), 3.42 (s, 3H, N + CH 3 ), 2.77 (s, 1H, CHC═), 2.28 (s, 1H, CHC═), 1.91-1.54 (m, 14H), 1.23 (s, 16H); 31 P NMR: δ −2.29; 13 C NMR: δ 147.2, 116.3, 65.7, 64.9, 60.7, 58.5, 48.3, 40.5, 39.8, 38.9, 37.3, 32.0, 30.9, 30.4, 29.7, 29.6, 29.5, 29.3, 28.6, 26.5, 25.8; ESI-MS m/z: 534.2 (M + +Na + ), 512.2(M + ).
Example 22
1-{2-{[(4-(Dodecyloxy)cyclohexyloxy)ethyloxy]hydroxyphosphinyloxy}ethyl}-1-methylpiperidinium inner salt
[0086] The general procedure described above using 2-[4-(dodecyloxy)cyclohexyloxy]ethanol, TIPS-Cl and N-(2-hydroxyethyl)-N-methylpiperidinium bromide afforded the compound named above (0.241 g, 45%). 1 H NMR: δ 4.26 (bs, 2H), 3.88-3.79 (m, 4H), 3.58-3.38 (m, 6H), 3.36-3.27 (m, 7H), 1.95-1.40 (m, 34H), 0.83 (t, J=7.0 Hz, 3H); 31 P NMR: δ −2.26.
Example 23
1-{2-{[(4-(Dodecyloxy)cyclohexyloxy)ethyloxy]hydroxyphosphinyloxy}ethyl}-1-methylmorpholinium inner salt
[0087] The general procedure described above using 2-[4-(dodecyloxy)cyclohexyloxy]ethanol, TIPS-Cl and N-(2-hydroxyethyl)-N-methylmorpholinium bromide afforded the compound named above (0.213 g, 40%). 1 H NMR: δ 4.32 (broad s, 2H), 4.04-3.19 (m, 21H), 1.99-1.50 (m, 28H), 0.86 (t, J=7.0 Hz, 3H, CH 3 ); 31 P NMR: δ −2.5.
Example 24
1-{2-{[(4-(Tetradecyloxy)cyclohexyloxy)ethyloxy]hydroxyphosphinyloxy}ethyl}-1-methylpiperidinium inner salt
[0088] The general procedure described above using 2-[4-(tetradecyloxy)cyclohexyloxy]ethanol, TIPS-Cl and choline chloride afforded the compound named above (0.214 g, 38%).
[0089] 1 H NMR: δ 4.31 (bs, 2H), 3.93-3.84 (m, 4H), 3.62-3.54 (m, 6H), 3.36-3.27 (m, 7H), 1.87-1.20 (m, 38H), 0.83 (t, J=7.0 Hz, 3H); 31 P NMR: δ −2.32.
Example 25
1-{2-{[(4-(Tetradecyloxy)cyclohexyloxy)ethyloxy]hydroxyphosphinyloxy}ethyl}-1-methylmorpholinium inner salt
[0090] The general procedure described above using 2-[4-(tetradecyloxy)cyclohexyloxy]ethanol, TIPS-Cl and N-(2-hydroxyethyl)-N-methylmorpholinium bromide afforded the compound named above (0.236 g, 42%). 1 H NMR: δ 4.32 (broad s, 2H), 3.96-3.19 (m, 21H), 1.89-1.50 (m, 32H), 0.86 (t, J=7.0 Hz, 31); 31 P NMR: δ −2.11.
[0000] General Procedure for the Hydrogenation of the Unsaturated Ether Phospholipids
[0091] To a solution of the desired ether phospholipid (1 mmol) in MEOH (10 mL) was added 10% Pd/C (10% w/w) and the resulting mixture was hydrogenated at 1 Atm for 10 h. Filtration through celite and evaporation of the filtrate in vacuo afforded the pure product.
Example 26
1-{2-{[(4-Dodecylcyclohexyloxy)ethyloxy]hydroxyphosphinyloxy}ethyl}-N,N,N-trimethylammonium inner salt
[0092] The general procedure described above using the compound of Example 1 afforded the compound named above (yield quantitative). 1 H NMR: δ: 4.31 (broad s, 2H, POCH 2 CH 2 N), 3.93 (broad s, 2H, CH 2 OPOCH 2 CH 2 N), 3.82 (broad s, 2H), 3.59 (broad s, 2H, POCH 2 CH 2 N), 3.37 (broad s, 10H, CHO, N + (CH 3 ) 3 ), 2.05-1.95 (m, 1H), 1.76-1.72 (m, 2H), 1.46-1.10 (m, 28H), 0.86 (t, J=7.0 Hz, 3H, CH 3 ).
Example 27
1-{2-{[(4-Tetradecylcyclohexyloxy)ethyloxy]hydroxyphosphinyloxy}ethyl}-N,N,N-trimethylammonium inner salt
[0093] The general procedure described above using the compound of Example 4 afforded the compound named above (yield quantitative). 1 H NMR: δ 4.31 (broad s, 2H, POCH 2 CH 2 N), 3.93-3.82 (m, 4H), 3.59-3.15 (m, 12H), 1.96 (broad s, 1H), 1.76 (broad s, 2H), 1.42-1.09 (m, 32H), 0.87 (t, J=7.0 Hz, 3H, CH 3 ).
Example 28
1-{2-[(11-Cyclohexylundecyloxy)hydroxyphosphinyloxy]ethyl}-N,N,N-trimethylammonium inner salt
[0094] The general procedure described above using the compound of Example 13 afforded the compound named above (yield quantitative). 1 H NMR: δ 4.20 (broad s, 2H, POCH 2 CH 2 N), 3.75-3.68 (m, 4H, CH 2 OPOCH 2 CH 2 N), 3.26 (s, 9H, N + (CH 3 ) 3 ), 2.09-1.12 (m, 13H), 1.23 (s, 18H, (CH 2 ) 9 ).
Example 29
1-{2-[(5-Adamantylpentyloxy)hydroxyphosphinyloxy]ethyl}-N,N,N-trimethylammonium inner salt
[0095] The general procedure described above using the compound of Example 16 afforded the compound named above (yield quantitative). 1 H NMR: a 4.27 (bs, 2H, POCH 2 CH 2 N), 3.79-3.09 (m, 13H), 2.02-1.25 (m, 23H).
Example 30
1-{2-[(11-Adamantylundecyloxy)hydroxyphosphinyloxy]ethyl-N,N,N-trimethylammonium inner salt
[0096] The general procedure described above using the compound of Example 19 afforded the compound named above (yield quantitative). 1 H NMR: δ 4.27 (broad s, 2H, POCH 2 CH 2 N), 3.79-3.09 (m, 13H), 2.02-1.25 (m, 35H).
[0000] Determination of in Vitro Antileishmanial Activity in Promastigote Cultures.
[0097] The effect of the phospholipids according to the present invention against the promastigote forms of Leishmania donovani and Leishmania infantum was evaluated using an MTT (3-(4,5-dimethylthiazol-2yl)-2,5-diphenyltetrazolium bromide)-based enzymatic method as a marker of cell viability and was compared with that of the ether phospholipid hexadecylphosphocholine (Miltefosine). Thus, promastigotes of Leishmania infantum MHOM/ITN/80/IPT1/LEM 235 and Leishmania donovani MHOM/TN/80/DD8/LEM 703, were grown in RPMI 1640 supplemented with 10% FCS, L. glutamine and antibiotics, at 26° C. All new compounds were dissolved in DMSO to a final concentration of 9.625 mM and linear 3-fold dilutions were done in the culture medium. 25 μL of promastigote culture at 5×10 5 cells/mL were cultured in a 96-well flat-bottom plate (Costar 3696), and incubated with 25 μL of different drug concentrations at 26° C. After 72 h, 10 μL of 5 mg/nL MTT in PBS (SIGMA M2128) were added and incubation was continued for 3 h. The reaction was stopped by the addition of 50 μL of 50% isopropanol, 10% SDS under gentle shacking for 30 min. Absorbance was measured at 550 nm with reference at 620 nm in a TRITURUS microplate reader.
TABLE 1 In vitro antileishmanial activity* against the promastigote forms of L. infantum and L. donovani of phospholipids of the present invention. IC 50 (μM) IC 50 (μM) L. infantum L. donovani Compound MON 235 MON 703 Miltefosine 22.56 ± 3.6 23.71 ± 4.07 1-{2-{[(4-Dodecylidenecyclohexyloxy)ethyloxy]hydroxy- 3.25 ± 0.65 7.08 ± 1.2 phosphinyloxy}ethyl}-N,N,N-trimethylammonium inner salt. 1-{2-{[(4-Dodecylidenecyclohexyloxy)ethyloxy]hydroxy- 23.07 ± 3.6 22 ± 3.25 phosphinyloxy}ethyl}-1-methylpiperidinium inner salt. 1-{2-{[(4-Dodecylidenecyclohexyloxy)ethyloxy]hydroxy- 16.46 ± 1.8 50.67 ± 3.6 phosphinyloxy}ethyl}-1-methylmorpholinium inner salt. 1-{2-{[(4-Tetradecylidenecyclohexyloxy)ethyloxy]hydroxy- 5.25 ± 0.45 3.91 ± 0.21 phosphinyloxy}ethyl}-N,N,N-trimethylammonium inner salt. 1-{2-{[(4-Tetradecylidenecyclohexyloxy)ethyloxy]hydroxy- 11.4 ± 2.4 29.7 ± 3.6 phosphinyloxy)ethyl}-1-methylpiperidinium inner salt. 1-{2-{[(4-Tetradecylidenecyclohexyloxy)ethyloxy]hydroxy- 15.5 ± 1.8 38.6 ± 3.2 phosphinyloxy)ethyl}-1-methylmorpholinium inner salt. 1-{2-{[(4-Hexadecylidenecyclohexyloxy)ethyloxy]hydroxyl- 21.19 ± 2.6 45.1 ± 7.2 phosphinyloxy)ethyl}-N,N,N-trimethylammonium inner salt. 1-{2-{[(4-Hexadecylidenecyclohexyloxy)ethyloxy]hydroxy- 6.5 ± 1.7 21.96 ± 1.99 phosphinyloxy}ethyl}-1-methylpiperidinium inner salt. 1-{2-{[(4-Hexadecylidenecyclohexyloxy)ethyloxy]hydroxy- 3.7 ± 0.71 16.22 ± 2.29 phosphinyloxy}ethyl}-1-methylmorpholinium inner salt. 1-{2-[(5-Cyclohexylidenepentyloxy)hydroxyphosphinyloxy]ethyl}-N,N,N- >100 >100 trimethylammonium inner salt. 1-{2-[(5-Cyclohexylidenepentyloxy)hydroxyphosphinyloxy]ethyl}-1- >100 >100 methylpiperidinium inner salt. 1-{2-[(5-Cyclohexylidenepentyloxy)hydroxyphosphinyloxy]ethyl}-1- >100 >100 methylmorpholinium inner salt. 1-{2-[(11-Cyclohexylideneundecyloxy)hydroxy- 5.2 ± 1.5 2.4 ± 0.6 phosphinyloxy]ethyl}-N,N,N-trimethylammonium inner salt. 1-{2-[(11-Cyclohexylideneundecyloxy)hydroxy- 47.6 ± 7.33 8.7 ± 1 phosphinyloxy]ethyl}-1-methylpiperidinium inner salt. 1-{2-[(11-Cyclohexylideneundecyloxy)hydroxy- 22.8 ± 1.7 8.25 ± 0.25 phosphinyloxy]ethyl}-1-methylmorpholinium inner salt. 1-{2-[(5-Adamantylidenepentyloxy)hydroxy- >100 4.99 ± 1.50 phosphinyloxy]ethyl}-N,N,N-trimethylammonium inner salt. 1-{2-[(5-Adamantylidenepentyloxy)hydroxy- >100 >100 phosphinyloxy]ethyl}-1-methylpiperidinium inner salt. 1-{2-[(5-Adamantylidenepentyloxy)hydroxy- >100 46.85 ± 8.7 phosphinyloxy]ethyl}-1-methylmorpholinium inner salt. 1-{2-[(11-Adamantylideneundecyloxy)hydroxy- 6.75 ± 2.4 3.16 ± 0.63 phosphinyloxy]ethyl}-N,N,N-trimethylammonium inner salt. 1-{2-[(11-Adamantylideneundecyloxy)hydroxy- 22.58 ± 3.4 5.41 ± 1.14 phosphinyloxy]ethyl}-1-methylpiperidinium inner salt. 1-{2-[(11-Adamantylideneundecyloxy)hydroxy- 6.64 ± 1.2 5.09 ± 1.86 phosphinyloxy]ethyl}-1-methylmorpholinium inner salt. 1-{2-{[(4-Dodecylcyclohexyloxy)ethyloxy]hydroxy- 5.65 ± 1.93 9.49 ± 1.4 phosphinyloxy}ethyl-N,N,N-trimethylammonium inner salt. 1-{2-{[(4-Tetradecylcyclohexyloxy)ethyloxy]hydroxy- 23.3 ± 3.5 23.65 ± 4.4 phosphinyloxy}ethyl}-N,N,N-trimethylammonium inner salt. 1-{2-[(11-Cyclohexylundecyloxy)hydroxyphosphinyloxy] 8.4 ± 0.8 10.3 ± 1.3 ethyl}-N,N,N-trimethylammonium inner salt. 1-{2-[(5-Adamantylpentyloxy)hydroxyphosphinyloxy]ethyl}- >100 4.02 ± 2.3 N,N,N-trimethylammonium inner salt. 1-{2-[(11-Adamantylundecyloxy)hydroxyphosphinyloxy] 5.97 ± 1.06 2.88 ± 0.72 ethyl}-N,N,N-trimethylammonium inner salt. *Results are expressed as mean ± SEM, n = 3-4 (each run in duplicate).
[0098] It is worth noting that the length of the alkyl chain of active compounds of the present invention varies from 5 to 11 carbon atoms for the alkylphosphocholine analogues and from 12 to 14 for the alkoxyethylphosphocholine analogues. This could be advantageous for the solubility and/or the toxicity of the new compounds and also for their metabolic clearance. Thus, we proceeded to assess the cytotoxicity of four inventive compounds as well as miltefosine in the human monocytic cell line THP1.
[0099] Assessment of Catotoxicity in THP1 Monocyte Cells.
[0100] As a quantitative measurement of the cell damage after incubation with different concentrations of drugs dual staining with SYBR-14 and PI (Molecular Probes, The Netherlands) was used followed by flow cytometry.
[0000] Staining with PI and SYBR-14
[0101] THP1 cell cultures were incubated at 1×10 6 cells/ml with different concentrations of the compounds ranging from 50 to 1.56. After an incubation period of 72 hours approximately 4×10 6 cells were suspended in labeling buffer (10 mM HEPES, 150 mM NaCl, 10% BSA, pH 7.4) and 10 μg/ml PI and 0.1 mg/ml SYBR-14 were added. The cultures were incubated at 37° C. for 30 minutes before analysis by flow cytometry.
[0000] Flow Cytometry Analysis.
[0102] Cell samples were analyzed on an Epics Elite model flow cytometer (Coulter, Miami, Fla.). The green fluorescence of SYBR-14 and the red fluorescence of PI were excited at 488 nm. At least 10,000 cells were analyzed per sample and each staining experiment was repeated twice. Data analysis was performed on fluorescence intensities that excluded cell autofluorescence and cell debris.
[0103] THP1 monocytes infected with the appropriate Leishmania species were used for the evaluation of the leishmanicidal activity of the compounds against the intracellular amastigote stages of the parasite. As shown in FIG. 1 , the evaluation of cytotoxic activity on infected THP1 monocytes with L. dontovani and L. infantum showed a very strong cytotoxic effect of miltefosine on THP1 cells at concentrations as low as 50 μM, which was not observed with two of the most active analogues (compounds 13 and 19) of the present invention. | Disclosed are novel ring containing phospholipids represented by the structural formula A-X—PO 3 —W and physiologically acceptable salts thereof and a process for the preparation of these compounds. The compounds can be used for the treatment of protozoal diseases and especially leishmaniasis. | 59,552 |
BACKGROUND
Building highly effective customer service applications, in an interactive voice response (IVR) system, is complex and expensive. The value of these investments is reduced when users fail to negotiate the IVR prompts correctly, ultimately having their transaction needs met by a call center agent. When the customer is served by an agent three things occur. First, the customer is not taught how to overcome the error generated in the IVR, so they are prone to invoke the more costly agent processing of their request in a subsequent transaction. Second, the customer's preference for agent supported transactions is rewarded, hence discouraging continued use of the IVR. And third, the agent serving the IVR can be occupied with completing all of the transactions needed by the customer on that interaction with the enterprise, thus, increasing operational expenses for the center.
Currently, when users experience problems using an IVR there are three solutions. First, the most commonly applied solution is to have the call transferred to an agent, and the agent handles all the transactions associated with that call for the customer. In this model, the IVR is abandoned for the transaction where the customer is forced out or presses zero (0) to exit the IVR. Second and less frequently, an agent takes the customer's call following the failed use of the IVR and completes the transaction with which the customer struggled. If the customer has multiple transactions to complete in that call, the agent generally transfers the customer back into the IVR to complete the subsequent transactions. Finally, the least frequent occurring solution is categorized as “Agent Assisted IVR.” In this method, dedicated call center agents are concurrently listening to multiple customer interactions within the IVRs. The customer is not aware that their interaction within the IVR is being monitored. When the customer experiences a problem, the agent tries to intervene by advancing the IVR script on the caller's behalf. This method has limited application. This method provides some opportunity to improve customer IVR usage. For example, the agent responds for a customer with a heavy accent that cannot be recognized by the IVR's speech engine. The heavy accent is, however, discernible by the monitoring agent, and the agent can “push” the call along to the appropriate next menu step, without interacting with the customer. However, this type of agent assistance is limited in its application. For example, if the customer cannot input their account number, the monitoring agent cannot correct the account number.
Typical solutions today do nothing to encourage or train the customer on how to use the IVR. These present methods do not change the likelihood that a customer will engage a more expensive call center agent when exiting IVR functions. The current solutions create five problems: (1) restarting interactions after the customer abandoned their progress in the IVR; (2) impeding the uptake of the IVR for service delivery (the customer continues to prefer to use a human agent); (3) preventing the customer from learning the IVR system; dissuading organizations from placing more complicated applications on the IVR system because complicated functions have higher user error rates; and (5) propagating the perception that IVR systems are poor service delivery mechanisms.
SUMMARY
It is with respect to the above issues and other problems that the embodiments presented herein were contemplated. A system is provided to conference a customer with the agent and the IVR system. The system can automatically monitor the customer's interaction with the IVR system. If needed, the system can automatically identify that the customer is having difficulties with the IVR script executed by the IVR system. In response, the system can then engage an agent, the IVR system, and the customer in a conference. The agent can direct responses to the IVR script. Rather than completing the interactions for the customer, the agent can instruct the customer on how to answer or interact with the IVR system.
The solution engages a live agent in a multi-party call type arrangement with the user and the IVR when the user makes an error in the IVR. The agent is provided with information about the IVR process being executed and the user's input. When the agent is introduced into the call, the agent does not take over the transaction, rather, the agent helps direct the user to provide the correct input to the IVR prompt. Once the issue is corrected, the agent can remove themselves from the customer/IVR dialogue. As a consequence: the user continues their self-service transactions in the IVR, and the user is better educated on how to navigate the IVR in the future. Further, agent resources are spared from supporting subsequent transactions within the same interaction with the user, and the user is less likely to have a negative opinion of the IVR so subsequent reuse is more probable.
The system and method has several advantages. The user is not diverted away from the IVR to be served by a call center agent. Rather, the agent is brought into the IVR dialogue for a very limited period of time to assist the user with the IVR dialogue. After the service is delivered, the agent is released and the user remains engaged with the IVR to complete the transaction. Progressively, customers will learn how to avoid IVR interaction errors and become more self-sufficient—reducing the resources needed to help customer complete IVR supported transactions.
The phrases “at least one”, “one or more”, and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.
The term “a” or “an” entity refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. It is also to be noted that the terms “comprising”, “including”, and “having” can be used interchangeably.
The term “automatic” and variations thereof, as used herein, refers to any process or operation done without material human input when the process or operation is performed. However, a process or operation can be automatic, even though performance of the process or operation uses material or immaterial human input, if the input is received before performance of the process or operation. Human input is deemed to be material if such input influences how the process or operation will be performed. Human input that consents to the performance of the process or operation is not deemed to be “material”.
The term “computer-readable medium” as used herein refers to any tangible storage that participates in providing instructions to a processor for execution. Such a medium may take many forms, including but not limited to, non-volatile media, volatile media, and transmission media. Non-volatile media includes, for example, NVRAM, or magnetic or optical disks. Volatile media includes dynamic memory, such as main memory. Common forms of computer-readable media include, for example, a floppy disk, a flexible disk, hard disk, magnetic tape, or any other magnetic medium, magneto-optical medium, a CD-ROM, any other optical medium, punch cards, paper tape, any other physical medium with patterns of holes, a RAM, a PROM, and EPROM, a FLASH-EPROM, a solid state medium like a memory card, any other memory chip or cartridge, or any other medium from which a computer can read. When the computer-readable media is configured as a database, it is to be understood that the database may be any type of database, such as relational, hierarchical, object-oriented, and/or the like. Accordingly, the embodiments are considered to include a tangible storage medium and prior art-recognized equivalents and successor media, in which the software implementations are stored.
The terms “determine”, “calculate” and “compute,” and variations thereof, as used herein, are used interchangeably and include any type of methodology, process, mathematical operation or technique.
The term “module” as used herein refers to any known or later developed hardware, software, firmware, artificial intelligence, fuzzy logic, or combination of hardware and software that is capable of performing the functionality associated with that element.
While exemplary embodiments are described, it should be appreciated that individual aspects can be separately claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The present disclosure is described in conjunction with the appended figures:
FIG. 1 is a block diagram of an embodiment of a contact center;
FIG. 2 is a block diagram of an embodiment of a contact center server;
FIG. 3 is another block diagram of an embodiment of a contact center server including a caller evaluation system;
FIG. 4 is a block diagram of an embodiment of a data structure for evaluating a caller for hiring into the contact center;
FIG. 5 is a flow diagram of an embodiment of a process for rating a caller and storing a personal profile of the caller that includes the rating;
FIG. 6 is a block diagram of an embodiment of a computer system environment in which the systems and methods may be executed; and
FIG. 7 is a block diagram of a computer system in which the systems and methods may be executed.
In the appended figures, similar components and/or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label by a letter that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.
DETAILED DESCRIPTION
The ensuing description provides embodiments only and is not intended to limit the scope, applicability, or configuration of the claims. Rather, the ensuing description will provide those skilled in the art with an enabling description for implementing the embodiments. It being understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the appended claims.
FIG. 1 shows an illustrative embodiment of a contact center 100 . A contact center 100 comprises a central server 110 , a set of data stores or databases 114 containing contact or customer related information and other information that can enhance the value and efficiency of the contact, and a plurality of servers, namely a voice mail server 126 , an Interactive Voice Response unit or IVR 122 , and other servers 124 , an outbound dialer 128 , a switch 130 , a plurality of working agents operating packet-switched (first) telecommunication devices 134 - 1 to 134 -N (such as computer work stations or personal computers), and/or circuit-switched (second) telecommunication devices 138 - 1 to 138 -M, all interconnected by a local area network LAN (or wide area network WAN) 142 . The servers can be connected via optional communication lines 146 to the switch 130 . As will be appreciated, the other servers 124 can also include a scanner (which is normally not connected to the switch 130 or Web server), VoIP software, video call software, voice messaging software, an IP voice server, a fax server, a web server, an instant messaging server, and an email server) and the like. The switch 130 is connected via a plurality of trunks 150 to the Public Switch Telecommunication Network or PSTN 154 and via link(s) 152 to the second telecommunication devices 138 - 1 to M. A gateway 158 is positioned between the server 110 and the packet-switched network 162 to process communications passing between the server 110 and the network 162 .
Referring to FIG. 2 , one possible configuration of the server 110 is depicted. The server 110 is in communication with a plurality of customer communication lines 200 a - y (which can be one or more trunks, phone lines, etc.) and agent communication line 204 (which can be a voice-and-data transmission line such as LAN 142 and/or a circuit switched voice line 146 ). The server 110 can include a Basic Call Management System or BCMS (not shown) and a Call Management System or CMS (not shown) that gathers call records and contact-center statistics for use in generating contact-center reports.
The switch 130 and/or server 110 can be any architecture for directing contacts to one or more telecommunication devices. Illustratively, the switch and/or server can be a modified form of the subscriber-premises equipment disclosed in U.S. Pat. Nos. 6,192,122; 6,173,053; 6,163,607; 5,982,873; 5,905,793; 5,828,747; and 5,206,903, all of which are incorporated herein by this reference in their entirety for all that they teach; Avaya Inc.'s Definity™ Private-Branch Exchange (PBX)-based ACD system; MultiVantage™ PBX, CRM Central 2000 Server™, Communication Manager™, Business Advocate™, Call Center™, Contact Center Express™, Interaction Center™, and/or S8300™, S8400™, S8500™, and S8700™ servers; or Nortel's Business Communications Manager Intelligent Contact Center™, Contact Center—Express™, Contact Center Manager Server™, Contact Center Portfolio™, and Messaging 100/150 Basic Contact Center™. Typically, the switch/server is a stored-program-controlled system that conventionally includes interfaces to external communication links, a communications switching fabric, service circuits (e.g., tone generators, announcement circuits, etc.), memory for storing control programs and data, and a processor (i.e., a computer) for executing the stored control programs to control the interfaces and the fabric and to provide automatic contact-distribution functionality. The switch and/or server typically include a network interface card (not shown) to provide services to the serviced telecommunication devices. Other types of known switches and servers are well known in the art and therefore not described in detail herein.
Referring again to FIG. 2 , included among the data stored in the server 110 is a set of contact queues 208 a - n and a separate set of agent queues 212 a - n . Each contact queue 208 a - n corresponds to a different set of agent skills, as does each agent queue 212 a - n . Conventionally, contacts are prioritized and are queued in individual ones of the contact queues 208 a - n in their respective orders of priority or are queued in different ones of a plurality of contact queues that correspond to a different priority. Likewise, each agent's skills are prioritized according to his or her level of expertise in that skill, and either agents are queued in individual ones of agent queues 212 a - n in their order of expertise level or are queued in different ones of a plurality of agent queues 212 a - n that correspond to a skill and each one of which corresponds to a different expertise level.
Included among the control programs in the server 110 is an agent and contact selector 220 (referred to hereinafter simply as the contact selector 220 ). Contacts incoming to the contact center, which are temporarily held in contact queue 216 , are assigned by contact selector 220 to different contact queues 208 a - n based upon a number of predetermined criteria, including customer identity, customer needs, contact center needs, current contact center queue lengths, customer value, and the agent skill that is required for the proper handling of the contact. The queues 208 a - n are part of a larger contact queue 217 . The predetermined criteria may be obtained by either automatic or initial human interaction to determine the needs of the customer. These criteria can be used to initially evaluate whether the customer is having difficulty with an IVR script and conference the customer with an agent as described in conjunction with FIGS. 3 through 5 .
Agents who are available for handling contacts are assigned to agent queues 212 a - n based upon the skills that they possess. An agent may have multiple skills, and hence may be assigned to multiple agent queues 212 a - n simultaneously. Furthermore, an agent may have different levels of skill expertise (e.g., skill levels 1-N in one configuration or merely primary skills and secondary skills in another configuration), and hence may be assigned to different agent queues 212 a - n at different expertise levels. Call vectoring is described in DEFINITY Communications System Generic 3 Call Vectoring/Expert Agent Selection (EAS) Guide, AT&T publication no. 555-230-520 (Issue 3, November 1993). Skills-based ACD is described in further detail in U.S. Pat. Nos. 6,173,053 and 5,206,903.
Referring again to FIG. 1 , the gateway 158 can be Avaya Inc.'s, G250™, G350™ G430™, G450™, G650™, G700™, and IG550™ Media Gateways and may be implemented as hardware such as via an adjunct processor (as shown) or as a chip in the server. The first telecommunication devices 134 - 1 , . . . 134 -N are packet-switched and can include, for example, IP hardphones such as the Avaya Inc.'s, 1600™, 4600™, and 5600™ Series IP Phones™, IP softphones such as Avaya Inc.'s, IP Softphone™, Personal Digital Assistants or PDAs, Personal Computers or PCs, laptops, packet-based H.320 video phones and conferencing units, packet-based voice messaging and response units, and packet-based traditional computer telephony adjuncts.
The second telecommunication devices 138 - 1 , . . . 138 -M are circuit-switched. Each of the telecommunication devices 138 - 1 , . . . 138 -M corresponds to one of a set of internal extensions Ext1, . . . ExtM, respectively. These extensions are referred to herein as “internal” in that they are extensions within the premises that are directly serviced by the switch. More particularly, these extensions correspond to conventional telecommunication device endpoints serviced by the switch/server, and the switch/server can direct incoming calls to and receive outgoing calls from these extensions in a conventional manner. The second telecommunication devices can include, for example, wired and wireless telephones, PDAs, H.320 video phones and conferencing units, voice messaging and response units, and traditional computer telephony adjuncts. Exemplary digital telecommunication devices include Avaya Inc.'s 2400™, 5400™, and 9600™ Series phones.
It should be noted that the embodiments do not require any particular type of information transport medium between the switch or the server and the first and the second telecommunication devices, i.e., the embodiments may be implemented with any desired type of transport medium as well as combinations of different types of transport media. The packet-switched network 162 can be any data and/or distributed processing network, such as the Internet. The network 162 typically includes proxies (not shown), registrars (not shown), and routers (not shown) for managing packet flows.
The packet-switched network 162 is in (wireless or wired) communication with an external first telecommunication device 174 via a gateway 178 , and the circuit-switched network 154 with an external (wired) second telecommunication device 180 and (wireless) third (customer) telecommunication device 184 . These telecommunication devices are referred to as “external” in that they are not directly supported as telecommunication device endpoints by the switch or server. The telecommunication devices 174 and 180 are an example of devices more generally referred to herein as “external endpoints.”
In some configurations, the server 110 , network 162 , and first telecommunication devices 134 are Session Initiation Protocol or SIP compatible and can include interfaces for various other protocols such as the Lightweight Directory Access Protocol or LDAP, H.248, H.323, Simple Mail Transfer Protocol or SMTP, IMAP4, ISDN, E1/T1, and analog line or trunk. It should be emphasized that the configuration of the switch, server, user telecommunication devices, and other elements as shown in FIG. 1 is for purposes of illustration only and should not be construed as limiting the embodiments to any particular arrangement of elements.
As will be appreciated, the central server 110 is notified via LAN 142 of an incoming contact by the telecommunications component (e.g., switch 130 , fax server, email server, web server, and/or other server) receiving the incoming contact. The incoming contact is held by the receiving telecommunications component until the server 110 forwards instructions to the component to forward or route the contact to a specific contact center resource, such as the IVR unit 122 , the voice mail server 126 , the instant messaging server, and/or first or second telecommunication device 134 , 138 associated with a selected agent. The server 110 distributes and connects these contacts to telecommunication devices of available agents based on the predetermined criteria noted above. When the central server 110 forwards a voice contact to an agent, the central server 110 also forwards customer-related information from databases 114 to the agent's computer work station for viewing (such as by a pop-up display) to permit the agent to better serve the customer. The agents process the contacts sent to them by the central server 110 . This embodiment is suited for a Customer Relationship Management (CRM) environment in which customers are permitted to use any media to contact a business. In a CRM environment, both real-time and non-real-time contacts must be handled and distributed with equal efficiency and effectiveness.
In embodiments, included among the programs executing on the server 110 are an agent and contact selector 220 and agent IVR conference module 232 . The selector 220 and agent IVR conference module 232 are stored either in the main memory or in a peripheral memory (e.g., disk, CD ROM, etc.) or some other computer-readable medium of the center 100 . The contact selector 220 and agent IVR conference module 232 collectively effect an assignment between available contacts in a queue and available agents serving the queue in a way that tends to maximize contact center efficiency. The selector 220 uses predefined criteria in selecting an appropriate agent to service the contact. The agent IVR conference module 232 assigns services priorities to contacts and, as part of this function, identifies contacts as disconnected or transitory contacts and determines whether such contacts merit special treatment. The agent IVR conference module 232 provides instructions to the selector 220 to effect the special treatment.
The agent IVR conference module 232 , based on one or more selected criteria, determines whether a contact should be placed in a conference with an agent to assist with an IVR. Special treatment includes providing the agent with materials or information to assist the customer, determine when and if the contact needs to have an agent assigned, etc. These and other embodiments are described in conjunction with FIG. 3 .
An embodiment of the central server 110 (referred to as “server”) in the contact center 100 , which includes an agent IVR conference module 232 , is shown in FIG. 3 . Generally, the agent IVR conference module 232 of the central server 110 , which may be a computer system as described in conjunction with FIGS. 6 and 7 , includes one or more software modules, components, etc. that are operable to assist callers with an IVR. However, in embodiments, the modules, components, etc. described in conjunction with FIG. 3 are embodied in specially designed hardware, such as a application specific integrated circuit (ASIC) or field programmable gate array (FPGA). However, the central server 110 is hereinafter described as a computer system executing software to provide the functionality, but the embodiments are not limited to these examples as one skilled in the art will understand.
An agent IVR conference system 232 is operable to communicate with a contact, an agent, a contact selector 220 , one or more skill queues 212 / 208 , and/or the interactive voice response unit 122 . The agent IVR conference system 232 is operable to monitor one or more customer contacts, which may have been placed in the contact queue 216 and then forwarded to or are using the interactive voice response unit 122 . The agent IVR conference system 232 can determine if the customer is having difficulty with the IVR script and may then either direct the contact selector 220 to route the contact into a conference that should include an IVR skilled agent in an agent queue 212 or simply send the contact to an agent. In other embodiments, the IVR script has the ability to direct a contact to an agent or conference with an agent. Thus, the customer is placed into a contact queue 217 and a skill queue 208 associated with IVR assistance. The agent is queued in the agent queue 212 , and the IVR system 122 may also be conferenced into the call. An embodiment of the IVR conference system 232 is as shown in FIG. 3 .
Referring to FIG. 3 , an agent IVR conference system 232 may be a module or system operated by a server or processor. The agent IVR conference system 232 can include one or more modules that may be executed in hardware or software. These modules may communicate with one another to conduct the operations described herein. In embodiments, the agent IVR conference system 232 includes an error recognition module 302 , a suspension module 304 , an IVR database 306 , a conference call module 308 , a second database 310 and/or an IP transfer module 312 . Each of these modules will be described herein after.
An error recognition module 302 is operable to monitor the IVR session conducted between the IVR response unit 122 and one or more customers operating telecommunication devices 174 / 180 . The error recognition module 302 can use one or more methods to determine if the customer is having trouble with the IVR script. In another embodiment, the IVR script/IVR application has the ability to monitor the IVR session and the functions of the error recognition module 302 are incorporated into the IVR script. In one embodiment, if the user presents one or more incorrect answers to responses in the IVR script, the error recognition module 302 can determine that the customer is having difficulty with the IVR script. If the customer is having trouble with the IVR script, the error recognition module 302 can signal the suspension module 304 that such difficulty has occurred. In embodiments, the error recognition module 302 may determine difficulty with the IVR script based on one or more predetermined rules stored in the rules database 310 .
The suspension module 304 is operable to suspend the IVR script. Thus, the suspension module, upon receiving a signal from the error recognition module 302 , can send a signal to the IVR unit 122 to suspend the IVR script. Further, the suspension module 304 can also receive inputs or commands from an agent communication device 134 / 138 . Thus, the agent communication device 134 / 138 can control the function of the suspension module 304 . The agent can reinitiate the IVR script, continue the suspension, cancel the IVR session or do one or more other tasks by interacting with the suspension module 304 .
An IVR database 306 can be any database as described in conjunction with FIGS. 6 and 7 . In embodiments, the IVR database 306 includes information about one or more communication sessions between the customer and the IVR unit 122 . This information can include customer information, IVR script information, information about responses to the current IVR script, questions asked during the IVR session, etc. Data stored within the IVR database 306 can be as described in conjunction with FIG. 4 .
The IP transfer module 312 is operable to transfer information to the agent communication device 134 / 138 . In embodiments, the IP transfer module 312 can obtain information from the IVR database 306 or other data sources to send to the agent communication device 134 / 138 . This information can include IVR script information, information about the current IVR session, information about the customer, or other information needed or requested by the agent communication device 134 / 138 to conduct or conference with the customer about the IVR script.
The rules database 310 is operable to store information about how to determine when an agent should assist with an IVR script. These rules may be predetermined by the user or standard for all Agent IVR Conference Systems 232 . Example rules can include if the user incorrectly answers a question two times, answers two sequential questions incorrectly, etc. then assistance is needed; if a user presses “0”, to obtain human assistance, two or more time in response to a question, then assistance is needed; or if a user goes back or forward through one or more questions, then assistance is needed. More rules are possible and contemplated. The rules can be categorized based on the customer, context of the assistance, or other data to better determine when assistance is required. Thus, the rules database 310 may provide the error recognition module 302 with some or all of the rules depending on the call.
A conference call module 308 is operable to conference the customer telecommunication device 170 / 180 with the IVR unit 122 and the agent communication device 134 / 138 . Thus, the conference call module 308 can bring the three different entities into one conference call and allow the agent to direct the customer actions with respect to the IVR script. The conference call module 308 may also conference in other agents or customers as needed. The conference call module 308 begins a conference upon direction of the error recognition module 302 or suspension module 304 when it is determined that a conference is needed because a customer is having trouble with an IVR script. The conference call module 308 is operable to communicate with the contact queue 216 , the agent and contact selector 220 , and one or more queues 208 / 212 to initiate and conduct a conference call.
An embodiment of a data structure 400 that may be received, sent, or stored while determining whether a caller requires assistance with an IVR session is shown in FIG. 4 . The one or more data structures described in conjunction with FIG. 4 can be any type of data structure including an object, a field, or other data structure in a relational database, a flat file database, etc. Here, each field within the data structure 400 is described as a portion of the data structure 400 . However, it should be understood by one skilled in the art, the portion can be a field, attribute, or other data structure according to the type of database used. The portions may include data associated with IVR process metadata 402 , customer information 404 , a first message 406 , a first response 408 , a second message 410 , and a second response 412 . There may be more or fewer items of data in the data structure 400 as represented by ellipses 414 . Further, each IVR session may include a separate data structure 400 that may be stored in the IVR database 306 . However, only a single data structure 400 is shown in FIG. 4 in order for simpler discussion and description of the data structure.
The IVR process metadata 402 can describe one or more items of information about the current IVR session or IVR script. For example, the IVR process metadata 402 can include a unique ID assigned to the IVR session, can include an identifier associated with the IVR script being executed during the IVR session, or other information that may be pertinent to the agent when the agent is trying to help the customer with the IVR session. The IVR process metadata 402 may be collected from the IVR unit 122 and stored in the IVR process metadata portion 402 . The agent may access the IVR process metadata 402 on an agent communication device 134 / 138 during the conference IVR session.
Customer information 404 can include one or more items of information about the customer currently engaged in the IVR session. The customer information 404 can include the customer's name, address, phone number, previous calls, or other information stored by the server 110 . Customer information 404 may be taken before the IVR session, obtained during the IVR session, or stored during previous calls and retrieved by the Agent IVR Conference System 232 .
The data structure 400 may also store one or more messages and responses that are part of the IVR script. For example, the IVR session may have requested information in a first message 406 and a second message 410 . The customer may have given information in response 408 and response 412 . By having the message and responses from the IVR script stored in the data structure 400 , the agent can deduce where the customer may have entered incorrect information or had trouble with the IVR script. Thus, the entire message/response session with the IVR script may be stored in one or more portions of the data structure 400 .
An embodiment of a method for conducting an agent conference IVR session is shown in FIG. 5 . Generally, the method 500 begins with a start operation 502 and terminates with an end operation 518 . While a general order for the steps of the method 500 is shown in FIG. 5 , the method 500 can include more or fewer steps or arrange the order of the steps differently than those shown in FIG. 5 . The method 500 can be executed as a set of computer-executable instructions executed by a computer system and encoded or stored on a computer readable medium. Hereinafter, the method 500 shall be explained with reference to the systems, components, modules, software, data structures, etc. described in conjunction with FIGS. 1-4 .
The server 110 receives a customer contact from a telecommunication device 174 / 180 , in step 504 . The customer contact can be a contact of any type of media but, in embodiments described hereinafter, is described as telephone call received through one or more networks 162 / 154 , possibly a switch 130 , a bus 142 , a gateway 178 , 158 , or one or more other devices. The customer contact can be directed from the server 110 into a contact queue 216 .
The server 110 may then determine that the customer contact is suitable for sending to an IVR unit 122 . The server 110 may then send the contact to the IVR unit 122 to have the IVR unit 122 interact with the customer. The IVR unit 122 can then present the customer with an IVR script, in step 506 . The IVR script may include one or more questions and require interactive responses from the customer. The customer may be able to enter information through voice responses or using a key pad. This information may be recorded by the IVR unit 122 and presented to the server 110 .
The server 110 may receive the information from the IVR unit 122 and provide it to an agent IVR conference system 232 . The error recognition module 302 of the agent IVR conference system 232 can analyze the information received from the IVR response unit 122 , to determine if the user is having trouble with the IVR script, in step 508 . Further, the agent IVR conference system 232 can store the received information in the IVR database 306 , in a data structure 400 . As the customer is interacting with the IVR unit 122 the error recognition module 302 can analyze the information to determine if the user is having trouble with the IVR script. For example, the error recognition module 302 can retrieve one or more rules from the rules database 310 and apply the rule(s) to the IVR session. For example, the error recognition module 302 can determine if the customer has entered one or more incorrect answers during the IVR script. If a customer has sequentially entered two or more incorrect answers, the customer may be having difficulty. In other examples, the error recognition module 302 can recognize the user has requested an operator or some other help during the IVR session. If the error recognition module determines that the user is having trouble with the IVR, step 508 proceeds “YES” to step 510 . If the error recognition module determines that the user is not having trouble with the IVR, step 508 proceeds “NO” to step 516 to continue the IVR while the error recognition module 302 continues to monitor the session.
A suspension module 304 can then receive a signal from the error recognition module 302 ; the signal can indicate that the user is having trouble with the IVR script. The signal directs the suspension module 304 to suspend the IVR script. The suspension module 304 may then send a signal to the IVR unit 122 to suspend the script. Further, the error recognition module 302 can send a signal to the agent and contact selector 220 to queue an agent into an agent queue 212 associated with IVR assistance. The agent, in embodiments, has skills in directing customers through IVR scripts. Further, the error recognition module 302 directs the agent and contact selector to queue the contact into a queue 208 to be placed in the conference. The error recognition module 302 then instructs the conference call module 308 to conference in the agent, customer, and IVR session into a conference call.
The agent contact selector 220 queues an IVR skilled agent into a skill queue 212 , in step 510 . The agent contact selector 220 may then inform the customer, in the queue 208 , that the agent is going to be included in the contact. In embodiments, one of the skill queues 212 is related to IVR systems. Further, one of the contact queues 208 is associated with help with the IVR session. When the agent is available, the agent contact selector 220 can inform the agent IVR conference system 232 to conduct the conference.
Upon receiving a signal that the agent is available, the conference call module 308 can create a conference call between the customer telecommunication device 174 / 180 , the IVR unit 122 , and the agent communication device 134 / 138 , in step 512 . The conference call includes each of the three entities and allows the agent to communicate with the customer about the IVR script. Further, the agent is operable to reinitiate the IVR script by instructing the suspension module 304 to start the IVR script, may continue to suspend the IVR script, may provide a different IVR script, may change or instruct the IVR script to change its execution or behavior, or do other actions to help the customer with their needs in providing information to the server 110 through the IVR session.
At some point thereinafter, the agent can disengage from the conference. The agent may disengage if the customer is able to then perform the rest of the IVR script and is allowed to complete the IVR script on their own, or may disengage if the agent handles the customer's call rather than continue with the IVR script. In embodiments, the method 500 shows the continuation of the method 500 if the agent disengages because the customer continues with the IVR script. Thus, the conference call module 308 can determine if the agents disengaged, in step 514 . If the agent is disengaged, step 514 proceeds “YES” to step 516 . If the agent is not disengaged, step 514 proceeds “NO” back to step 512 where the conference continues with the agent, the IVR unit 122 , and the customer.
In step 516 , the customer continues with the IVR script. Thus, the customer is able to answer further questions and respond to the questions until the IVR script is completed, a new IVR script is started, or the customer needs help again. The information about the continued IVR session continues to be stored in the data structure 400 , and the information continues to be sent from the IVR unit 122 to the agent IVR conference system 232 . The customer may need help again in which case the method 500 may start over at step 508 .
The computers, computer systems, servers, devices, and/or components that are described herein and that may execute the processes described herein may be as described in conjunction with FIGS. 6 and 7 . FIG. 6 illustrates a block diagram of a computing environment 600 . The system 600 includes one or more computers 605 , 610 , and 615 . The computers 605 , 610 , and 615 may be general purpose personal computers (including, merely by way of example, personal computers and/or laptop computers running various versions of Microsoft Corp.'s Windows® and/or Apple Corp.'s Macintosh® operating systems) and/or workstation computers running any of a variety of commercially-available UNIX® or UNIX-like operating systems. These computers 605 , 610 , 615 may also have any of a variety of applications, including for example, database client and/or server applications, and web browser applications. Alternatively, the computers 605 , 610 , and 615 may be any other electronic device, such as a thin-client computer, mobile telephone, mobile device, Internet-enabled mobile telephone, and/or personal digital assistant, capable of communicating via a network (e.g., the network 620 described below) and/or displaying and navigating web pages or other types of electronic data. Although the exemplary system 600 is shown with three computers, any number of computers may be supported.
System 600 further includes a network 620 . The network 620 may can be any type of network familiar to those skilled in the art that can support data communications using any of a variety of commercially-available protocols, including without limitation TCP/IP, SNA, IPX, AppleTalk, and the like. Merely by way of example, the network 620 maybe a local area network (“LAN”), such as an Ethernet network, a Token-Ring network and/or the like; a wide-area network; a virtual network, including without limitation a virtual private network (“VPN”); the Internet; an intranet; an extranet; a public switched telephone network (“PSTN”); an infra-red network; a wireless network (e.g., a network operating under any of the IEEE 802.11 suite of protocols, the Bluetooth® protocol known in the art, and/or any other wireless protocol); and/or any combination of these and/or other networks.
The system 600 may also include one or more server computers 625 and 630 . The server computers 625 and/or 630 can represent the customer service server 102 . One server may be a web server 625 , which may be used to process requests for web pages or other electronic documents from user computers 605 , 610 , and 620 . The web server can be running an operating system including any of those discussed above, as well as any commercially-available server operating systems. The web server 625 can also run a variety of server applications, including HTTP servers, FTP servers, CGI servers, database servers, Java servers, and the like. In some instances, the web server 625 may publish operations available operations as one or more web services.
The system 600 may also include one or more file and or/application servers 630 , which can, in addition to an operating system, include one or more applications accessible by a client running on one or more of the user computers 605 , 610 , 615 . The server(s) 630 may be one or more general purpose computers capable of executing programs or scripts in response to the user computers 605 , 610 and 615 . As one example, the server may execute one or more web applications. The web application may be implemented as one or more scripts or programs written in any programming language, such as Java™, C, C# or C++, and/or any scripting language, such as Perl, Python, or TCL, as well as combinations of any programming/scripting languages. The application server(s) 630 may also include database servers, including without limitation those commercially available from Oracle, Microsoft, Sybase™, IBM™ and the like, which can process requests from database clients running on a user computer 605 .
The web pages created by the web application server 630 may be forwarded to a user computer 605 via a web server 625 . Similarly, the web server 625 may be able to receive web page requests, web services invocations, and/or input data from a user computer 605 and can forward the web page requests and/or input data to the web application server 630 . In further embodiments, the server 630 may function as a file server. Although for ease of description, FIG. 6 illustrates a separate web server 625 and file/application server 630 , those skilled in the art will recognize that the functions described with respect to servers 625 , 630 may be performed by a single server and/or a plurality of specialized servers, depending on implementation-specific needs and parameters.
The system 600 may also include a database 635 . The database 635 may reside in a variety of locations. By way of example, database 635 may reside on a storage medium local to (and/or resident in) one or more of the computers 605 , 610 , 615 , 625 , 630 . Alternatively, it may be remote from any or all of the computers 605 , 610 , 615 , 625 , 630 , and in communication (e.g., via the network 620 ) with one or more of these. In a particular set of embodiments, the database 635 may reside in a storage-area network (“SAN”) familiar to those skilled in the art. Similarly, any necessary files for performing the functions attributed to the computers 605 , 610 , 615 , 625 , 630 may be stored locally on the respective computer and/or remotely, as appropriate. In one set of embodiments, the database 635 may be a relational database, such as Oracle 10i®, that is adapted to store, update, and retrieve data in response to SQL-formatted commands.
FIG. 7 illustrates one embodiment of a computer system 700 upon which the test system may be deployed or executed. The computer system 700 is shown comprising hardware elements that may be electrically coupled via a bus 755 . The hardware elements may include one or more central processing units (CPUs) 705 ; one or more input devices 710 (e.g., a mouse, a keyboard, etc.); and one or more output devices 715 (e.g., a display device, a printer, etc.). The computer system 700 may also include one or more storage devices 720 . By way of example, storage device(s) 720 may be disk drives, optical storage devices, solid-state storage devices, such as a random access memory (“RAM”) and/or a read-only memory (“ROM”), which can be programmable, flash-updateable, and/or the like.
The computer system 700 may additionally include a computer-readable storage media reader 725 ; a communications system 730 (e.g., a modem, a network card (wireless or wired), an infra-red communication device, etc.); and working memory 740 , which may include RAM and ROM devices as described above. In some embodiments, the computer system 700 may also include a processing acceleration unit 735 , which can include a DSP, a special-purpose processor and/or the like
The computer-readable storage media reader 725 can further be connected to a computer-readable storage medium, together (and, optionally, in combination with storage device(s) 720 ) comprehensively representing remote, local, fixed, and/or removable storage devices plus storage media for temporarily and/or more permanently containing computer-readable information. The communications system 730 may permit data to be exchanged with the network 720 and/or any other computer described above with respect to the system 700 . Moreover, as disclosed herein, the term “storage medium” may represent one or more devices for storing data, including read only memory (ROM), random access memory (RAM), magnetic RAM, core memory, magnetic disk storage mediums, optical storage mediums, flash memory devices, and/or other machine readable mediums for storing information.
The computer system 700 may also comprise software elements, shown as being currently located within a working memory 740 , including an operating system 745 and/or other code 750 , such as program code implementing the components and software described herein. It should be appreciated that alternate embodiments of a computer system 700 may have numerous variations from that described above. For example, customized hardware might also be used and/or particular elements might be implemented in hardware, software (including portable software, such as applets), or both. Further, connection to other computing devices such as network input/output devices may be employed.
In the foregoing description, for the purposes of illustration, methods were described in a particular order. It should be appreciated that in alternate embodiments, the methods may be performed in a different order than that described. It should also be appreciated that the methods described above may be performed by hardware components or may be embodied in sequences of computer-readable or machine-executable instructions, which may be used to cause a machine, such as a general-purpose or special-purpose processor or logic circuits programmed with the instructions to perform the methods. These computer-readable or machine-executable instructions may be stored on one or more machine readable mediums, such as CD-ROMs or other type of optical disks, floppy diskettes, ROMs, RAMs, EPROMs, EEPROMs, magnetic or optical cards, flash memory, or other types of computer-readable or machine-readable mediums suitable for storing electronic instructions. Alternatively, the methods may be performed by a combination of hardware and software.
Furthermore, embodiments may be implemented by hardware, software, firmware, middleware, microcode, hardware description languages, or any combination thereof. When implemented in software, firmware, middleware or microcode, the program code or code segments to perform the necessary tasks may be stored in a machine readable medium such as storage medium. A processor(s) may perform the necessary tasks. A code segment may represent a procedure, a function, a subprogram, a program, a routine, a subroutine, a module, a software package, a class, or any combination of instructions, data structures, or program statements. A code segment may be coupled to another code segment or a hardware circuit by passing and/or receiving information, data, arguments, parameters, or memory contents. Information, arguments, parameters, data, etc. may be passed, forwarded, or transmitted via any suitable means including memory sharing, message passing, token passing, network transmission, etc.
Also, it is noted that the embodiments were described as a process which is depicted as a flowchart, a flow diagram, a data flow diagram, a structure diagram, or a block diagram. Although a flowchart may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be re-arranged. A process is terminated when its operations are completed, but could have additional steps not included in the figure. A process may correspond to a method, a function, a procedure, a subroutine, a subprogram, etc. When a process corresponds to a function, its termination corresponds to a return of the function to the calling function or the main function.
Specific details were given in the description to provide a thorough understanding of the embodiments. However, it will be understood by one of ordinary skill in the art that the embodiments may be practiced without these specific details. For example, circuits may be shown in block diagrams in order not to obscure the embodiments in unnecessary detail. In other instances, well-known circuits, processes, algorithms, structures, and techniques may be shown without unnecessary detail in order to avoid obscuring the embodiments.
While illustrative embodiments have 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 as limited by the prior art. | A system engages a live agent in a multi-party call type arrangement with the user and an Interactive Voice Response (IVR) unit when the user has difficulty with the IVR. The agent is provided with information about the IVR process being executed and the user's input. When the agent is introduced into the call, the agent does not take over the IVR session, but the agent helps direct the user to provide the correct input(s) to the IVR session. Once the issue is corrected, the agent can remove themself from the customer/IVR dialog. As a consequence: the user continues their self-service transactions in the IVR, and the user is better educated on how to navigate the IVR in the future. Further, agent resources are spared from further interaction with the user, and the user is less likely to have a negative opinion of the IVR. | 53,575 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a computer network, and more particularly, to a network-device management apparatus and method relating to a network-device management program for controlling network devices connected to a computer network.
2. Description of the Related Art
Today, computers are often interconnected via a local area network (LAN). The local area network is constructed in a floor or the entirety of a building, a group of buildings (an enclosure), a local area, or a larger area. It is also possible to interconnect such networks, and connect the networks to a worldwide network. Each of such interconnected LANs has, in some cases, various hardware interconnecting techniques and a plurality of network protocols.
In a simple LAN isolated from other LANs, each user can exchange an apparatus, install software, or examine problems.
On the other hand, in a large-scale complicated LAN or a large group of interconnected LANs, “management” is required. The word “management” indicates management by both a network device manager (a human being), and software used by that manager.
In the present invention, the word “management” indicates management by software (a network-device management program) for managing the entire system, and the word “user” indicates a human being who uses the network-device management program. Usually, the user is a network-device manager or a person responsible for system management. By using a network-device management program, the user can obtain management data from each network device and change the management data.
Usually, a large-scale network system is a dynamic system in which addition or removal of an apparatus, updating of software, detection of problems, and the like are incessantly performed. A description will now be provided of a large-scale network which requires “management”.
FIG. 1 is a diagram illustrating a large-scale network. Usually, a printer 102 having an open architecture is connected to a network via a network board (NB) 101 . The NB 101 is connected to a LAN 100 via a LAN interface, such as an Ethernet interface 10Base-2 having a coaxial connector, or 10Base-T having RJ-45, or the like.
A plurality of personal computers (PCs), such as a PC 103 , a PC 104 and the like, are also connected to the LAN 100 . These PC 103 , PC 204 and the like can communicate with the NB 101 under the control of a network operating device. The user can use the PC 103 as a PC for managing network devices. A local printer 105 is connected to the PC 104 . Similarly, a local printer, such as the printer 105 or the like, may be connected to the PC 103 , although such is not shown in FIG. 1 .
A file server 106 is also connected to the LAN 100 . The file server 106 manages access to a file stored in a large-capacity (for example, ten billion bytes) network disk 107 . A print server 108 manages printing requests to a plurality of printers 109 , the printer 105 installed at a remote location, and the like. Any other peripheral apparatus (not shown) may also be connected to the LAN 100 .
A WWW (world wide web) server 150 is also connected to the LAN 100 . The WWW server 150 transmits an HTML (Hyper Text Markup Language) document generated by an installed network-device management program to the PC 103 , which can display the HTML document on a display by means of an installed WWW browser. Alternatively, when the user performs setting of a printer using the WWW browser in the PC 103 , the PC 103 can transmit the contents of the setting to a specific printer via the network-device management program of the WWW server 150 .
More specifically, in the network shown in FIG. 1 , in order to perform efficient communication between various network members, network software, such as Novell®, NetWare®, UNIX® or the like, may be used. Although any network software may be used, NetWare (a registered trademark of the Novell Corporation; hereinafter omitted) software is an example of software that is fully suited for this use. For more detailed description relating to this software package, refer to the on-line documentation enclosed in the NetWare package). This documentation can be purchased from the Novell Corporation together with the NetWare package.
FIG. 1 will now be briefly described. The file server 106 operates as a file management unit, and performs reception, storage, queuing, caching, and transmission of files. For example, data files formed by each of the PC 103 and PC 104 are transmitted to the file server 106 . The file server 106 sequentially arranges these data files and performs queuing, and sequentially transmits the data files to a printer 109 in accordance with a command from the print server 108 .
Each of the PC 103 and PC 104 is an ordinary PC which can perform generation of a data file, transmission of the generated data file to the LAN 100 , reception of files from the LAN 100 , and display and/or processing of the received files.
Although only PCs are illustrated in FIG. 1 , any other computers which are suitable for executing network software may also be connected to the network. For example, when UNIX software is used, UNIX workstations may be connected to the network. Such workstations may be used together with the illustrated PCs in an appropriate situation.
Usually, the LAN provides a relatively local user group, for example, a user group on a single floor or on a plurality of consecutive floors within a building with service. As the distance between users increases, for example, when users are located in different buildings or prefectures, a wide-area network (WAN) may be constructed. A WAN is basically an aggregate of LANs formed by interconnecting various LANs with a high-speed digital network, such as ISDN (Integrated Services Digital Network) or the like. Accordingly, as shown in FIG. 1 , a WAN is formed by interconnecting the LAN 100 , a LAN 110 and a LAN 120 via modem/transponders 130 , 130 b and a backbone 140 .
Dedicated PCs, and if necessary, a file server and a print server, are connected to each of the LANs. As shown in FIG. 1 , a PC 111 , a PC 112 , a file server 113 , a network disk 114 , a print server 115 and a number of printers 116 are connected to the LAN 110 . On the other hand, only a PC 121 and a PC 122 are connected to the LAN 120 . The devices connected to the LAN 100 , the LAN 110 and the LAN 120 can access the functions of apparatuses connected to other LANs via the WAN connection.
In order to manage devices connected to networks constituting such a large-scale network system, various attempts have been made by a large number of standardization organizations. The International Organization for Standardization (ISO) has provided a general-purpose standard framework called an Open System Interconnection (OSI) model. The OSI model of a network-device control protocol is called a Common Management Information Protocol (CMIP). The CMIP is a network-device control protocol common in Europe.
Recently, a modification of the CMIP, called a Simple Network Management Protocol (SNMP), has been used as a network-device management protocol capable of being more commonly used (see the first edition, Aug. 20, 1992, of “Introduction to TCP/IP Network-Device Management: Aiming at Practical Management” written by M. T. Rose, translated by Takeshi Nishida, published by Toppan Printing Company, Limited).
A network-device management system according to this SNMP network-device management technique includes at least one network-device management station (NMS), a plurality of nodes to be managed, each including an agent, and a network-device management protocol to be used by the network-device management station and the agent for exchanging management information. Usually, the user can obtain data on the network or change the data by communicating with agent software on a node to be managed using a network-device management program in the NMS.
The word “agent” indicates software running at each node to be managed as a background process. When the user requests management data to a device on the network, the network-device management program puts object identifying information in a management packet or frame, and transmits the packet or frame to the agent of the device. The agent interprets the object identifying information, puts data corresponding to the object identifying information in a packet, and transmits the packet to the network-device management program. The agent calls, in some cases, a corresponding process in order to extract data.
The agent holds management data relating to the state of the device in the form of a database. This database is called an MIB (management information base). The MIB has the data structure of a tree, in which all nodes are uniquely numbered. An identifier for each of the nodes is called an object identifier.
The structure of the MIB is called a Structure of Management Information (SMI), which is provided in “RFC1155 Structure and Identification of Management Information for TCP/IP-Based Internets”.
In this specification, management data for a network device is equivalent to information allocated to the MIB object identifier (MIB information).
Next, the SNMP will be briefly described. Communication is performed between a PC (manager) where the network-device management program operates and a network device (agent) to be managed where an SNMP agent operates using the SNMP. The SNMP has five types of commands, i.e., Get-request, Get-next-request, Get-response, Set-request, and Trap.
Get-request and Get-next-request commands are commands to be transmitted from the manager to the agent in order for the manager to acquire the value of the MIB object (MIB information) of the agent. The agent which has received this command transmits a Get-response command in order to notify the manager of the value of the MIB object.
A Set-request command is a command transmitted from the manager to the agent in order for the manager to set the value of the MIB object of the agent. The agent which has received this command sets the value of the MIB object, and transmits a Get-response command to the manager in order to notify the manager of the result of the setting.
A Trap command is a command transmitted from the agent to the manager in order to notify the manager of a change in the state of the agent's own device.
A system is well known in which the SNMP agent operates in the printer itself or the network board (NB 101 ) connected to the printer, and the network-device management program, serving as the SNMP manager, operates in the PC.
SUMMARY OF THE INVENTION
In accordance with recent spread of use of the Internet, a system has been proposed in which a dedicated network-device management program operates in a server, and a WWW browser is used as a user interface. An outline of the operation of an ordinary WWW system and the operation of an SNMP management program based on the WWW system will now be described with reference to FIG. 2 .
In FIG. 2 , a WWW server program 1501 operates in a PC 150 . A large number of WWW page data (WWW documents or templates for generating respective WWW documents) described using the HTML are stored on a hard disk of the PC 150 .
In order to display a page assigned by the user, a WWW browser program 1031 requests the WWW server program 1501 operating in the PC 150 to acquire page data of the assigned page.
The WWW server program 1501 transmits the assigned page data in response to the request from the WWW browser program 1031 . The WWW browser program 1031 analyzes the acquired page data and displays the page based on the description.
When a request using a CGI (Common Gateway Interface) is included within the request to acquire the page data from the WWW browser program 1031 , the WWW server program 1501 starts an external script or program using the CGI. The WWW server program 1501 then acquires page data generated by the external script or program, and transmits the acquired data to the WWW browser program 1031 .
Next, a description will be provided of a case in which the external program started by the CGI is a network-device management program.
A network-device management program 1502 started by the WWW server program 1501 using the CGI acquires management data from a device connected to the network, for example, a printer 102 , using the SNMP. The network-device management program 1502 generates page data described by the HTML (hereinafter termed an “HTML document”) based on the acquired management data, and transmits the generated data to the WWW server program 1501 .
FIGS. 9 and 10 illustrate examples of display of HTML documents generated by the network-device management program 1502 . FIG. 9 is an example of display of a device list in which a summary of network devices connected to the network is displayed. In this example, MIB information, including the device name, the product name, the network interface board name, the network address and the state, is acquired from each network device connected to the network, and the acquired information is displayed.
FIG. 10 is an example of display of the details of each device performed when the user has selected a specific device in the display shown in FIG. 9 , in order to display further details of the selected device. In the case of FIG. 10 , the state of the network device (printer), the status of mounting of optional devices, the states of sheet feeding and discharging units, and the like are acquired as MIB information, and display is performed based on the acquired MIB information.
If the network-device management program 1502 utilizing the WWW system acquires management data from a network device every time a request to display MIB information is provided from the WWW browser program 1031 , too much time is required from the request of display to display of management data. Accordingly, the network-device managment program 1502 preserves management data acquired from a device to be managed in a memory (RAM (random access memory)) or a hard disk (HD) in a local PC (a device storing data, such as a RAM, a HD or the like, will be hereinafter termed a “cache”, and data stored therein will be hereinafter termed a “cache file”). Instead of newly acquiring management data from a device to be managed, the network-device management program 1502 generates an HTML document using management data preserved in the cache for a specific period from the acquisition of the management data.
In this approach, a problem arises in that the user cannot know when management data displayed on the WWW browser as shown in FIG. 9 or 10 which has been acquired from a network device by the network-device management program that uses the cache was acquired from the network device.
For example, even if management data obtained by the user by starting the WWW browser is management data which has been just displayed on the WWW browser via the network-device management program of the WWW server (the user feels as if the displayed data is information newly acquired from the network device), there is the possibility that the displayed data is actually old management data acquired from the network device by the network-device control program a few hours before, based on a request from another WWW browser.
To the contrary, even if information displayed on the WWW browser is information just now acquired from the network device by the network-device management program based on a request from the WWW browser, the user cannot know if the management data in the network device coincides with the management data displayed on the WWW browser (i.e., if the very latest information is displayed). Accordingly, there arises a problem in that the user may unnecessarily provide a command to “update to latest information” (the user can instruct the network-device management program to generate an HTML document by newly acquiring management data by depressing a button 903 shown in FIG. 9 or a button 1003 shown in FIG. 10 , instead of merely reaquiring the HTML document), thereby increasing the load on the network-device management program operating in the WWW server beyond what is necessary.
It is an object of the present invention to provide a network-device management apparatus and method using a cache represented by a network-device management program in a WWW system or the like, in which the above-described problems are solved.
According to one aspect of the present invention, a network-device management method for managing network devices connected to a network includes an acquisition step, of acquiring device information relating to a network device, a time acquisition step, of acquiring time data substantially indicating a time of acquisition of the device information, and a conversion step, of converting the device information and the time data into a form conforming to a predetermined display format.
According to another aspect of the present invention, in a method for controlling a network-device management system including a network-device management apparatus for managing network devices connected to a network, and an information processing apparatus capable of displaying device information relating to a network device managed by the network-device management apparatus, a method for controlling the network-device management apparatus includes a reception step, of receiving a command from the information processing apparatus, an acquisition step of acquiring the device information, a time acquisition step, of acquiring time data substantially indicating a time of acquisition of the device information, a conversion step, of converting the device information and the time data into a form conforming to a predetermined display format, and a transmission step, of transmitting the device information and the time data to the image processing apparatus in the form after being converted in the conversion step. A method for controlling the image processing apparatus includes a command transmission step of transmitting the command to the network-device management apparatus, and an information reception step, of receiving the device information and the time data in the converted form.
According to still another aspect of the present invention, a network-device management apparatus for managing network devices connected to a network includes acquisition means for acquiring device information relating to a network device, time acquisition means for acquiring time data substantially indicating a time of acquisition of the device information, and conversion means for converting the device information and the time data into a form conforming to a predetermined display format.
According to yet another aspect of the present invention, in a network-device management system including a network-device management apparatus for managing network devices connected to a network, and an information processing apparatus capable of displaying device information relating to a network device managed by the network-device management apparatus, the network-device management apparatus includes reception means for receiving a command from the information processing apparatus, acquisition means for acquiring the device information, time acquisition means for acquiring time data substantially indicating a time of acquisition of the device information, conversion means for converting the device information and the time data into a form conforming to a predetermined display format, and transmission means for transmitting the device information and the time data to the image processing apparatus in the form after being converted by the conversion means. The image processing apparatus includes command transmission means for transmitting the command to the network-device management apparatus, and information reception means for receiving the device information and the time data in the form after being converted.
According to yet a further aspect of the present invention, in a recording medium storing a network-device management program for managing network devices connected to a network, the network-device management program includes an acquisition step, of acquiring device information relating to a network device, a time acquisition step, of acquiring time data substantially indicating a time of acquisition of the device information, and a conversion step, of converting the device information and the time data into a form conforming to a predetermined display format.
According to still another aspect of the present invention, in a recording medium storing programs for a network-device management system including a network-device management apparatus for managing network devices connected to a network, and an information processing apparatus capable of displaying device information relating to a network device managed by the network-device management apparatus, a program in the network-device management apparatus includes a reception step, of receiving a command from the information processing apparatus, an acquisition step, of acquiring the device information, a time acquisition step, of acquiring time data substantially indicating a time of acquisition of the device information, a conversion step, of converting the device information and the time data into a form conforming to a predetermined display format, and a transmission step, of transmitting the device information and the time data to the image processing apparatus in the form after being converted in the conversion step. A program in the image processing apparatus includes a command transmission step, of transmitting the command to the network-device management apparatus, and an information reception step, of receiving the device information and the time data in the converted form.
According to still another aspect of the present invention, in a transmission apparatus for transmitting a network-device management program for managing network devices connected to a network, the network-device management program includes an acquisition step, of acquiring device information relating to a network device, a time acquisition step, of acquiring time data substantially indicating a time of acquisition of the device information, and a conversion step, of converting the device information and the time data into a form conforming to a predetermined display format.
According to still another aspect of the present invention, in a transmission apparatus for transmitting programs for a network-device management system including a network-device management apparatus for managing network devices connected to a network, and an information processing apparatus capable of displaying device information relating to a network device managed by the network-device management apparatus, a program in the network-device management apparatus includes a reception step of receiving a command from the information processing apparatus, an acquisition step, of acquiring the device information, a time acquisition step, of acquiring time data substantially indicating a time of acquisition of the device information, a conversion step, of converting the device information and the time data into a form conforming to a predetermined display format, and a transmission step, of transmitting the device information and the time data to the image processing apparatus in the form after being converted in the conversion step. A program in the image processing apparatus includes a command transmission step of transmitting the command to the network-device management apparatus, and an information reception step, of receiving the device information and the time data in the converted form.
The foregoing and other objects, advantages and features of the present invention will become more apparent from the following description of the preferred embodiment taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustrating the configuration of a LAN;
FIG. 2 is a block diagram illustrating an outline of the operation of an ordinary WWW system and the operation of a network-device management program based on the WWW system;
FIG. 3 is a block diagram illustrating the configuration of a PC, in which a network-device management program can operate, according to an embodiment of the present invention;
FIG. 4 is a block diagram illustrating the configuration of each module of a network-device management program according to that embodiment;
FIG. 5 is a flowchart illustrating processing of acquiring management data from a network device in that embodiment;
FIG. 6 is a flowchart for a case in which management data is preserved in a form before being converted into information for display when generating the information for display in response to a request from a client, in that embodiment;
FIG. 7 is a flowchart when management data is preserved in a form after being converted into information for display in that embodiment;
FIG. 8 is a flowchart when the form of preserving management data can be changed according to information for display in that embodiment;
FIG. 9 is a diagram illustrating an example of display of a device list in which a summary of network devices to be managed that are connected to a network is displayed;
FIG. 10 is a diagram illustrating an example of display of the details of a network device, in which further detailed information of the device is displayed;
FIG. 11 is a diagram illustrating an example of display of a device list generated by a network-device management program in the embodiment of FIG. 3 ;
FIG. 12 is a diagram illustrating an example of display of the details of a device generated by the network-device management program in that embodiment;
FIG. 13 is a diagram illustrating an image of a memory map of a storage medium storing the network-device management program in that embodiment; and
FIG. 14 is a diagram illustrating a storage medium storing program codes, and a transmission apparatus for transmitting the program codes.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A network-device management method according to an embodiment of the present invention will now be described. Particularly, a description will be provided of a network-device management method using a WWW system with reference to the drawings.
A network-device management method or apparatus according to the present invention is realized by PCs having the same configuration as PCs which can realize a conventional network-device management apparatus, as shown in FIG. 3 .
In FIG. 3 , a network-device management program operates in a PC 150 , which is equivalent to the PC 150 shown in FIG. 1 . A CPU (central processing unit) 301 executes a network-device management program stored in a storage medium, such as a ROM (read-only memory) 302 , a hard disk (HD) 311 , a floppy disk (FD) 312 or the like, and controls respective devices connected to a system bus 304 .
A RAM 303 operates as a main memory, a working area or the like for the CPU 301 . A keyboard controller (KBC) 305 controls input from a keyboard (KB) 309 or a pointing device (not shown). A CRT (cathode-ray tube) controller (CRTC) 306 controls display on a CRT display (CRT) 310 . A disk controller (DKC) controls access to the hard disk (HD) 311 and the floppy disk (FD) 312 storing boot programs, various application programs, editing files, user files, the network-device management program and the like. A network interface card (NIC) 308 performs two-way data exchange with an agent or a network device via a LAN 100 .
In the following description, unless otherwise mentioned, the subject of execution in hardware is the CPU 3012 , and the subject of execution in software is the network-device management program stored in the hard disk (HD) 311 .
In FIG. 1 , a combination, for example, of the network board (NB) 101 connected to the network and the printer 102 where the network board 101 is mounted is termed a network device.
FIG. 4 is a diagram illustrating the configuration of each module of a network-device management program 1502 of the embodiment. The network-device management program 1502 of the embodiment is stored in the HD 311 shown in FIG. 3 , and is executed by the CPU 301 . At that time, the CPU 301 uses the RAM 303 as a working area.
In FIG. 4 , the network-device management program 1502 is started from a WWW server program 1501 , and exchanges CGI parameters and HTML documents with the WWW server program 1501 via a CGI (common gateway interface) 402 .
An overall control module 403 registers a CGI parameter for a parameter module (to be described later), and then allocates control to one of a system module 405 , a device-list module 407 and a device-detail module 409 (to be described later) in accordance with a command parameter within the CGI parameter.
If there is an error in the CGI parameter, the overall control module 403 generates, in some cases, an HTML document indicating the presence of error in the CGI parameter via a template module 412 (to be described later).
A parameter module 404 preserves/manages CGI parameters registered by the overall control module 403 in the form of a table. Any other module can acquire a desired parameter from the parameter module 404 whenever necessary.
The system module 405 controls display/setting of system parameters for defining the operation of the network-device management program 1502 (such as the interval of automatic updating of an HTML document, and the like), and generates a related HTML document via the template module 412 .
The system module 405 acquires a command parameter from the parameter module 404 . When the contents of the acquired command parameter indicate a request to display a system parameter, the system module 405 reads necessary information from a system setting file 406 , and generates and HTML document for system parameter display via the template module 412 . When the contents of the acquired command parameter indicate a request to set a system parameter, the system module 405 writes the notified system parameter in the system setting file 406 , and generates an HTML document to be displayed after setting via the template module 412 .
Although not illustrated in FIG. 4 , a system parameter preserved in the system setting file 406 can be read by each module constituting the network-device management program 1502 , whenever necessary.
The device-list module 407 generates an HTML document indicating a summary of devices (device list) retrieved by a device-discovery module 408 (to be described below) via the template module 412 . Processing of optional display of the device list, and the like are also controlled by the device-list module 407 .
A device-discovery module 408 discovers a network device connected to the network.
The device-detail module 409 performs control for displaying/setting detailed information relating to a specific network device assigned by a CGI parameter, and generates a related HTML document via the template module 412 . In order to acquire/set detailed information relating to the assigned device, the device-detail module 409 uses a device specific module 410 (to be described below) corresponding to the assigned network device.
A device specific module 410 is provided for each device (a printer, a network interface board or the like) to be managed by the network-device management program. When displaying device-detail information, the device specific module 410 acquires necessary information from the device, and provides the template module 412 with the acquired information. When setting a setting value for the network device, the device specific module 410 converts the setting value notified in a CGI parameter into a value capable of being interpreted by the network device, and transmits the obtained value to the device.
A protocol module 411 performs control of various protocols necessary for the network-device management program to communicate with the network device, such as handling of MIB, transmission/reception of an SNMP packet, control of a transport protocol, and the like.
The template module 412 generates an HTML module as a result of output of the network-device management program, based on a template file 413 preserved in the hard disk 311 shown in FIG. 3 .
The template module 412 opens a template file assigned by a CGI parameter, the entire control module 403 , the system module 405 , the device-list module 407 or the device-detail module 409 , and analyzes the contents of the template file. The template module 412 also generates an HTML document by replacing a template variable contained in the template file by a value transmitted from the entire control module 403 , the system module 405 , the device-list module 407 , the device-detail module 409 or the device specific module 410 , whenever necessary. The generated HTML document is transmitted to the WWW server program via the CGI interface 402 .
The value of the template variable used when generating the HTML document or the generated HTML document file can also be preserved on the hard disk 311 shown in FIG. 3 as a cache file 414 . Thus, processing time when generating an HTML document at the second or later time based on the same template file is shortened.
Next, a description will be provided of the processing of the network-device management program when preserving the template variable or the management data used when generating the HTML document on the hard disk 311 as a cache file, with reference to FIGS. 5 and 6 . FIG. 5 is a flowchart illustrating the processing of acquisition of management data from a network device by the network-device management program.
In step S 501 , Get-request and Get-next-request commands are transmitted to the concerned network device. By receiving a Get-response command, management data of the network device is acquired via the network.
Although not illustrated in FIG. 5 , when a Get-response command expected for the Get-request and Get-next-request commands could not be received, appropriate error recovery processing, for example, retransmission of commands, is, of course, performed. Usually, a network device is assigned in the form of a network address or the like as a CGI parameter.
In step S 502 , system-time data (time of acquisition of management data) of the WWW server when the processing of the above-described step S 501 has been completed is acquired.
In step S 503 , the management data acquired in the above-described step S 501 and the management-data acquisition time acquired in the above-described step S 502 are preserved as the cache file 414 shown in FIG. 4 . It is assumed that the contents of the cache file 414 are preserved and can be referred to for each type of request from the WWW browser.
FIG. 6 is a flowchart illustrating the processing of generating an HTML document for displaying network-device management data in accordance with a request from the WWW browser by the network-device management program of the embodiment.
In step S 601 , it is determined if management data corresponding to the request for display (management data necessary for a page requested to be displayed) is present in the cache file. If the result of the determination in step S 601 is affirmative, the process proceeds to step s 602 . If the result of the determination in step S 601 is negative, the process proceeds to step S 603 .
In step S 602 , aquisition-time data of management data corresponding to the request for display within the cache file is compared with the system time (the current time) of the WWW server. When the management data is acquired within a specific period before the current time, i.e., relatively new information, the process proceeds to step S 604 . When the management data is not acquired within the specific period, i.e., old information, the process proceeds to step S 603 .
The specific period, i.e., an effective period for data preserved in the cache file 414 , may be determined so as to be inherent in the system of the network-device management program, or may be set by the user, for example, according to a system setting page of the network-device management program.
In step S 603 , the processing of acquiring information relating to the requested management data shown in FIG. 5 is executed.
In step S 604 , the requested management data is read from the cache file 414 .
In step S 605 , data relating to the acquisition time of the requested management data in the cache file 414 is read, and the process proceeds to step S 606 .
In step S 606 , the management data read in the above-described step S 604 and the acquisition-time data read in the above-described step S 605 are converted into a form capable of being displayed on the WWW browser (for example, an HTML document), and an HTML document is generated and output.
In the flowcharts shown in FIGS. 5 and 6 , after newly acquiring the management data and the acquisition-time data in the information acquisition processing, the acquired data is prevserved in the cache, and the preserved data is then read to form an HTML document. However, after generating an HTML document from the newly acquired data (the management data and the acquisition-time data), the acquired data (the management data and the acquisition-time data) may be preserved in the cache.
FIG. 7 is a flowchart illustrating the processing of generating an HTML document for displaying network-device management data in response to a request from the WWW browser by the network-device management program, when the generated HTML document is preserved on the hard disk as the cache file 414 .
In step S 701 , it is determined if the HTML document for a page requested to be displayed is present in the cache. If the result of the determination in step S 701 is affirmative, the process proceeds to step S 702 . If the result of the determination in step S 701 is negative, the process proceeds to step S 704 .
In step S 702 , data relating to the acquisition time of management data for the HTML document within the cache file (data relating to the generation time of the HTML document may be used assuming that the generation time of the HTML document is the acquisition time of the management data) is compared with the system time (the current time) of the WWW server. When the management data is acquired within a specific period before the current time, i.e., is relatively new information, the process proceeds to step S 703 . When the management data is not acquired within the specific period, i.e., old information, the process proceeds to step S 704 .
The specific period, i.e., an effective period for data preserved in the cache file 414 , may be determined so as to be inherent in the system of the network-device management program, or may be set by the user, for example, according to a system setting page of the network-device management program.
In step S 703 , the HTML document for a page requested to be displayed is read from the cache file and is output.
In step S 704 , Get-request and Get-next-request commands are transmitted to the concerned network device, and a Get-response command is received. Then, management data of the network device is acquired via the network. Although not illustrated in FIG. 7 , when a Get-response command expected for the Get-request and Get-next-request commands could not be received, appropriate error recovery processing, for example, retransmission of commands, is, of course, performed. Usually, a network device is assigned in the form of a network address or the like as a CGI parameter.
In step S 705 , the system time data (the time of acquisition of the management data) of the WWW server when the processing of the above-described step S 704 has been completed is acquired.
In step S 706 , using the management data acquired in the above-described step S 704 and the management-data acquisition time acquired in the above-described step S 705 , an HTML document (in a form capable of being displayed on the WWW browser) is generated and output.
In step S 707 , the HTML document generated in the above-described step S 706 is preserved as a cache file, and the processing is terminated.
In the above-described description with reference to FIG. 7 , the management-data acquisition time is compared with the current time, and it is determined if the acquired management data is a document within an effective period. However, the management-data acquisition time may be obtained by reading data contained within the HTML document, or a file for managing the time may be formed and used separately from the HTML document.
In the flowchart shown in FIG. 7 , after generating and outputting the HTML document in steps S 706 and S 707 , the HTML document is preserved. However, a configuration may, of course, be adopted in which after generating and preserving the HTML document, the HTML document is read and output.
When preserving data in the cache, the data is preferably preserved in the form of an HTML document or as the value of a template variable depending on the type of information for display. For example, when it is necessary to frequently change management data within information for display, the data may be preserved as the value of a template variable, and when it is unnecessary to frequently change the management data, the data may be preserved in the form of an HTML document.
FIG. 8 is a flowchart in which either one of the processing shown in FIGS. 5 and 6 and the processing shown in FIG. 7 is selected depending on information to be displayed.
In step S 801 , it is determined if information for display (an HTML document is a type of information for display) requested to be displayed is to be preserved in the form of an HTML document in the cache. If the result of the determination in step S 801 is affirmative, the process proceeds to step S 802 . If the result of the determination in step S 801 is negative, the process proceeds to step S 803 .
In step S 802 , the display requesting processing shown in FIG. 7 is executed, and the process is then terminated. In step S 803 , the display requesting processing shown in FIGS. 5 and 6 is executed, and the process is then terminated.
Although a description has been provided with reference to the flowcharts shown in FIGS. 5 through 8 , any other time may be used as the acquisition-time data, provided that the used time can be dealt with as a time substantially the same as the time of acquisition of management data. For example, when management data is acquired and immediately preserved as in the case of FIG. 5 , the time of preservation may be dealt with as the time of acquisition without causing any problem. When management data is acquired and information for display is immediately generated and preserved as in the case of FIG. 7 , the time of preservation of the information for display may be dealt with as the time of acquisition without causing any problem.
Acquisition-time data may be acquired/preserved for a plurality of management data (a group of management data) within information for display (for example, an HTML document), for each management data within information for display, or for each information for display.
When determining whether or not management data or information for display preserved in the cache is old, acquisition-time data preserved in order to be used for information for display may be used. Alternatively, time data which can be substantially dealt with as the acquisition time may be preserved as different data to be used for the determination.
In the aboved-described embodiment, generated/preserved information for display may be in the form of an HTML documentation, or in any other form capable of being displayed on the WWW browser (an HTML format, a text format, an image format or the like).
In the preferred embodiment, it is assumed that the network-device management program is operated on the WWW server and information for display is displayed on the WWW browser. However, the present invention may, of course, be used in order that a network-device management program in a server/client system other than the WWW system, a network-device management program using a cache, or the like notifies the user of when managment data displayed on a display picture surface has been acquired.
In the above-described embodiment, in order to indicate whether or not management data preserved in a cache module within a network-device management program is old, time data is displayed in information for display. However, when the network-device management program side does not have a cache, and a display program (such as a WWW browser or the like) at the client side has a mechanism for preserving information for display, time data may be substantially contained in information for display in order to indicate when management data contained in information for display has been acquired. In this case, also, as in the above-described embodiment, it is possible to prevent the user from executing an unnecessary “update to latest information” command, reduce the load of the network device or the network-device management program, and reduce traffic in the network.
FIG. 11 illustrates an example of display of a device list generated by the network-device management program in this embodiment. FIG. 12 illustrates an example of display of device details generated by the network-device management program in this embodiment.
In FIG. 11 , reference numeral 1105 represents the time of acquisition of management data from each network device subjected to summary display by the network-device management program. In FIG. 12 , reference numeral 1204 represents the time of acquisition of detailed information of management data from the concerned network device by the network-device management program.
The user can confirm how new displayed management data is by confirming the displayed time. The user can also execute a command for updating information to the latest information whenever necessary (by depressing a button 1103 or 1203 ).
The network-device management program of the embodiment may also be executed by a PC having a configuration equivalent to the configuration of the PC 150 shown in FIG. 5 according to a program installed from the outside. In such a case, the objects of the present invention may, of course, be achieved by supplying a system or an apparatus with a storage medium, such as a storage medium 1402 shown in FIG. 14 , storing program codes of software for realizing the functions of the above-described embodiment, and reading and executing the program codes stored in the storage medium by means of a computer (or a CPU or an MPU (microprocessor unit)) of the system or the apparatus.
In such a case, the program codes themselves read from the storage medium realize the functions of the above-described embodiment, so that the storage medium storing the program codes constitutes the present invention.
For example, a magnetic disk, such as a floppy disk, a hard disk or the like, an optical disk, a magnetooptical disk, a CD(compact disc)-ROM, a CD-R (recordable), a DVD(digital versatile disc)-ROM, a DVD-RAM, a magnetic tape, a memory card, a ROM or the like may be used as the storage medium for supplying the program codes.
The present invention may, of course, be applied to a case in which a program is distributed from storage medium storing program codes of software for realizing the functions of the above-described embodiment via a communication line for PC communication or the like.
FIG. 13 is a diagram illustrating a memory map of a storage medium, such as a CD-ROM or the like. In FIG. 13 , a region 1301 stores directory information which indicates the positions of a region 1302 storing an install program and a region storing a network-device management program 1303 . When the network-device management program of the embodiment is installed in a PC equivalent to the PC 150 shown in FIG. 3 , first, the install program stored in the region 1302 is loaded into the PC, and is executed by the CPU 301 . Then, the install program executed by the CPU 301 reads the network-device management program from the region 1303 storing the network-device management program, and stores the read program onto the hard disk 311 .
When the present invention is applied to the above-described storage medium, program codes corresponding to the above-described flowcharts are stored in the storage medium. Briefly speaking, each module as that shown in the example of the module configuration of FIG. 4 is stored in the storage medium.
The objects of the present invention may, of course, be applied to a case in which, as shown in FIG. 14 , a transmission apparatus 1404 , such as an HTTP (Hyper Text Transfer Protocol) server, an FTP (File Transfer Protocol) server or the like, transmits program codes of software for realizing the various functions of the above-described embodiment, a computer (or a CPU or an MPU) of the system or the apparatus receives the transmitted program codes via a network, a public network, radio transmission or the like represented by reference numeral 1405 , the computer executes the program codes.
In such a case, the program codes themselves transmitted from the transmission apparatus realize the functions of the above-described embodiment, so that the transmission apparatus for ttransmitting the program codes constitutes the present invention.
The present invention may be applied to a system or a composite apparatus comprising a plurality of apparatuses (such as a host computer, an interface apparatus, a reader and the like) or to an apparatus comprising a single unit.
The present invention may be applied not only to a case in which the functions of the above-described embodiment are realized by executing program codes read by a computer, but also to a case in which an OS (operating system) or the like operating in a computer executes a part or the entirety of actual processing, and the functions of the above-described embodiment are realized by the processing.
The present invention may also be applied to a case in which, after writing program codes read from a storage medium into a memory provided in a function expanding board inserted in a computer or in a function expanding unit connected to the computer, a CPU or the like provided in the function expanding board or the function expanding unit performs a part or the entirety of actual processing, and the functions of the above-described embodiment are realized by the processing.
As described above, accoring to the present invention, it is possible to display time data substantially indicating the time of acquisition of device information in information for display for displaying the device information (management data).
According to an instruction from the client side (user side), the information for display can be displayed at the client side.
By allowing preservation of device information, it is possible to reduce the number of acquisition of device information.
It is also possible to preserve device information in a form before conversion into information for display or in a form after conversion into information for display, so as to be convenient for processing.
By allowing automatic change of the form of preservation depending on the type of device information, the efficiency in display processing can be improved.
By automatically determining whether or not preserved device information is old, it is possible to display device information acquired within a predetermined period.
In the determination, by preserving time data to be used as a criterion for the determination separately from the acquired time data, it is possible to efficiently perform the determination.
If the determination is performed based on the above-described acquisition-time data without preserving time data as a criterion for the determination, it is possible to reduce the capacity of a memory for preserving the data.
Since the substantial time of acquisition of device information may be used as the acquisition time if there is little differece between the two types of times, time acquisition processing can be appropriately performed.
By generating and transmitting information for display when a command from a client has been received, it is possible to reduce the load of the management program and the network device.
By peforming transmission/reception with the client via the WWW server program, the client side need not newly introduce a program for displaying device information if an existent WWW browser has been introduced.
By thus indicating the time of acquisition of device information from a network device, it is possible to reduce the number of operations of transmitting a command to cause the network-device management program to acquire device information from a client (user), and efficiently preserve management data. Hence, it is possible to reduce the load on the network traffic and the network-device management program, the load on the network device, and the like.
The individual components shown in outline or designated by blocks in the drawings are all well known in the network-device management apparatus and method, recording medium, and transmission apparatus arts and their specific construction and operation are not critical to the operation or the best mode for carrying out the invention.
While the present invention has been desribed with respect to what is presently considered to be the preferred embodiment, it is to be understood that the invention is not limited to the disclosed embodiment. To the contrary, the present invention is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. The scope of the following claims is to be accorded the broadest interpretations so as to encompass all such modifications and equivalent structures and functions. | In a management system for managing network devices connected to a network, it is considered to reduce the load of the network and the devices by preserving device information acquired from each device and not acquiring new information from the device for a predetermined period. However, this approach has a problem in that the user cannot know when the displayed information was acquired. In the present invention, when preserving device information, the time of acquisition of the device information is preserved as acquisition-time data, which is displayed within displayed information together with the device information. The above-described probem is thereby solved, and the user can acquire very reliable information. | 55,251 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an electrical connector and an electrical connector assembly, more particularly to an electrical connector and an electrical connector assembly for power transmission.
[0003] 2. Description of Related Art
[0004] Electrical connectors are widely used today. In general, electrical connectors can be classified into personal use and industrial use. When in personal use, electrical connectors can be classified as desktop connectors, laptop connectors, mobile phone connectors, consuming connectors, and other types. When in industrial use, electrical connectors can be used in industrial computers, servers, and workstations. Power connector is one common kind of electrical connector used in different equipments. Usually, a plug-type power connector and a receptacle-type power connector mate with each other to supply power to the equipments. Contacts of the plug connector and the receptacle connector contact one another to form electrical connection.
[0005] China Patent No. CN200820212432.9 disclosed a plug connector and a receptacle connector mating with each other for power transmission. The plug connector comprises a plug insulative housing and a plurality of plug contacts received in the plug insulative housing for power transmission. The plug insulative housing defines a receiving cavity for receiving the receptacle connector. The plug contact is of slice structure and extends into the receiving cavity for electrically connecting with the receptacle connector. Since the slice-shape plug contacts are exposed into the receiving cavity directly without any protection to contacting ends thereof, the contacting ends are prone to be contacted when in improper use status. Therefore, electric shock phenomenon has great possibility to be generated and the contacting ends are easy to be polluted or damaged. It is more serious when the connectors are used for high-power, high-voltage situations.
[0006] Europe Patent No. EP1703597A1 disclosed a power connector comprising an insulative housing and a plurality of contacts assembled in the insulative housing. A one-piece retainer is assembled to the insulative housing and has protecting sections partially covering the front ends of contacting portions and upper and lower surfaces of the contacts. The retainer protects the contacting portions of the contacts from being touched unintendedly. Also, the protected contacting portions of the contacts also can avoid arc-discharge generation which is capable of influencing safe power transmission. The patent assures the contacts not to be touched from outside and also assures that the contacts not to be polluted or damaged for safe power transmission. However, the retainer is of one-piece structure and needs to align with all the contacting portions of the contacts before assembled to the insulative housing which adds the difficulty of assembly. Further, the contacting portions of the contacts are only partially covered by the retainer. The uncovered parts of the contacting portions of the contacts are still very close to the outside and easy to be polluted or damaged. Also, the one-piece structure has relative slim figure and insufficient strength which is not good enough. Further, when one contact is out of use, the whole retainer needs to be removed for repair which is not convenient enough.
[0007] Hence, it is disable to design an electrical connector and an electrical connector assembly to address problems mentioned above.
BRIEF SUMMARY OF THE INVENTION
[0008] Accordingly, an object of the present invention is to provide an electrical connector with improved protection means for providing reliable power transmission.
[0009] Another object of the present invention is to provide an electrical connector assembly with improved protection means for providing reliable power transmission.
[0010] In order to achieve the above-mentioned object, an electrical connector comprises an insulative housing, at least one contact and at least one protecting insulator. The insulative housing defines a mating direction, a mating face and a receiving cavity recessed from the mating face along said mating direction. The at least one contact is received in the insulative housing and comprises a contacting portion exposed into the receiving cavity, a retaining portion extending from one end of the contacting portion to be interferentially received in insulative housing, a forward end extending from the other end of the contacting portion to locate more closely to the mating face of the insulative housing than the contacting portion, and a connecting portion extending from the retaining portion to be exposed beyond the insulative housing. The protecting insulator entirely covers the forward end of the at least one contact.
[0011] In order to achieve the above-mentioned object, an electrical connector assembly comprises a plug connector and a receptacle connector mating with the plug connector. The plug connector comprises a first insulative housing defining a mating face and a receiving cavity recessed along a mating direction from the mating face, at leas one first contact received in the first insulative housing, and at least one protecting insulator. The at least one first contact comprises a first contacting portion exposed in the receiving cavity, a first retaining portion extending from one end of the first contacting portion and retained in the first insulative housing, a forward end extending from the other end of the first contacting portion to be closer to the mating face than the first contacting portion. The at least one protecting insulator entirely covers the forward end of the at least one contact. The receptacle connector comprises a second insulative housing, and at least one second contact received in the second insulative housing. The at least one second contact comprises an elastic second contacting portion electrically connecting with the at least one first contact. The second insulative housing is received in the receiving cavity of the first insulative housing, and the elastic second contacting portion of the at least second contact slides along the protecting insulator then forms electrical connection with the first contacting portion of the at least one first contact.
[0012] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter, which form the subject of the claims of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
[0014] FIG. 1 is an assembled, perspective view of an electrical connector assembly in accordance with the first embodiment of the present invention, wherein a plug connector (electrical connector) and a receptacle connector (electrical connector) of the electrical connector assembly are in mating status;
[0015] FIG. 2 is a view similar to FIG. 1 , but viewed from a different aspect;
[0016] FIG. 3 is a perspective view of the electrical connector assembly with the plug connector and the receptacle connector in separate status;
[0017] FIG. 4 is a view similar to FIG. 3 , but viewed from a different aspect;
[0018] FIG. 5 is an exploded, perspective view of the plug connector in accordance with the first embodiment of the present invention;
[0019] FIG. 6 is an exploded, perspective view of a first contact and a protecting insulator of the plug connector;
[0020] FIG. 7 is an exploded, perspective view of the receptacle connector (electrical connector) in accordance with a first embodiment of the present invention;
[0021] FIG. 8 is a cross-section view taken along line 8 - 8 of FIG. 1 ;
[0022] FIG. 9 is an assembled, perspective view of an electrical connector assembly in accordance with the second embodiment of the present invention;
[0023] FIG. 10 is an exploded, perspective view of a plug connector in accordance with the second embodiment of the present invention;
[0024] FIG. 11 is a view similar to FIG. 10 , but viewed from a different aspect;
[0025] FIG. 12 is a perspective view of an additional grounding contact of the plug connector;
[0026] FIG. 13 is an assembled, perspective view of the plug connector in accordance with the second embodiment of the present invention;
[0027] FIG. 14 is an exploded, perspective view of the receptacle connector in accordance with the second embodiment of the present invention;
[0028] FIG. 15 is a view similar to FIG. 14 , but viewed from a different aspect;
[0029] FIG. 16 is an assembled, perspective view of FIG. 15 ; and
[0030] FIG. 17 is a cross-section view taken along line 17 - 17 of FIG. 9 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] In the following description, numerous specific details are set forth to provide a thorough understanding of the present invention. However, it will be obvious to those skilled in the art that the present invention may be practiced without such specific details. In other instances, well-known circuits have been shown in block diagram form in order not to obscure the present invention in unnecessary detail. For the most part, details concerning timing considerations and the like have been omitted inasmuch as such details are not necessary to obtain a complete understanding of the present invention and are within the skills of persons of ordinary skill in the relevant art.
[0032] Reference will be made to the drawing figures to describe the present invention in detail, wherein depicted elements are not necessarily shown to scale and wherein like or similar elements are designated by same or similar reference numeral through the several views and same or similar terminology.
[0033] Referring to FIGS. 1-4 , an electrical connector assembly 100 in accordance with the first embodiment of the present invention comprises a plug connector 10 and a receptacle connector 20 mating with each other. The plug connector 10 and the receptacle connector 20 are power connectors for power transmission in the preferred embodiment of the present invention, but the connectors are not only restricted to power type connectors. Also, the plug connector 10 and the receptacle connector 20 are the electrical connectors in accordance with the present invention.
[0034] In the first embodiment of the present invention, the plug connector 10 comprises a first insulative housing 1 , a plurality of first contacts 2 attached to the first insulative housing 1 , and an additional grounding contact 4 also attached to the first insulative housing 1 . The receptacle connector 20 comprises a second insulative housing 6 and a plurality of second contacts 7 attached to the second insulative housing 6 . The first contacts 2 and the additional grounding contact 4 electrically connect with the second contacts 7 for power transmission.
[0035] please refer to FIGS. 1-2 , 4 - 5 and 8 , the first insulative housing 1 defines a first mating face 11 , a receiving cavity 12 recessed rearward from the first mating face 11 , and a surrounding rib 13 enlarged from the circumferential edges of the receiving cavity 12 . The receiving cavity 12 is circumscribed by opposite top wall 111 and bottom wall 112 , a pair of opposite sidewalls 113 , and a rear wall 114 . The bottom wall 112 defines a rectangular recess 14 behind the surrounding rib 13 . A plurality of horizontal and vertical partition racks 115 extend into the receiving cavity 12 to divide the receiving cavity 12 into three first contact-receiving passageways 121 arranged in triangle relationship for receiving the first contacts 2 and penetrating through the rear wall 114 . The horizontal and vertical partition racks 115 connect with one another to assure that at least two adjacent sides of each first contact 2 are surrounded by the partition racks 115 .
[0036] Please refer to FIGS. 5-6 and 8 , the first contacts 2 are three power contacts arranged in triangle relationship and received in the first contact-receiving passageways 121 . The two first contacts 2 aligning with each other and arranged on the same horizontal line are a positive contact and a negative contact in power transmission. The first contact 2 located at the top of the triangle is a grounding contact in power transmission. Each first contact 2 is of straight shape with a certain height and comprises a first retaining portion 21 interferentially engaged with the rear wall 114 of the first insulative housing 1 , a first connecting portion 22 extending rearward from the first retaining portion 21 to be exposed beyond the rear wall 114 for electrically connecting with wires (not shown), a flat first contacting portion 23 extending forward from the first retaining portion 21 , and a forward end 24 extending forward from the first contacting portion 23 ( FIG. 6 ). The forward end 24 is shrunk from the first contacting portion 23 with width and thickness both smaller that those of the first contacting portion 23 . The first contacting portion 23 has a contacting surface 231 behind the forward end 24 . When the first contacts 2 are retained in the first insulative housing 1 , the contacting portions 23 and the forward ends 24 are all exposed in the receiving cavity 12 , the connecting portions 22 extend beyond the rear wall 114 . The forward end 24 ha a front face 241 close to the first mating face 11 and an extending face 242 located at the same side as that of the contacting surface 231 .
[0037] Since the forward ends 24 are located closer to the first mating face 11 , the forward ends 24 are easier to be touched by fingers or other things, or covered by dust from outside, all cause the forward ends 24 (especially the front faces 241 thereof) are prone to be polluted or damaged, further influence the stability of power transmission or raise unsafe problems. Please refer to FIGS. 5 and 6 , a protecting insulator 3 is overmolded with the forward end 24 of the first contact 2 in the preferred embodiment of the present invention which protects the forward end 24 from the problems described above. Of course, in an alternative embodiment, the protecting insulators 3 also can be assembled to the forward ends 24 of the first contacts 2 . The protecting insulator 3 is a hollow cuboid with one open end toward the forward end 24 of the first contact 2 . The protecting insulator 3 comprises a front end portion 31 covering the front face 241 of the forward end 24 and a cover portion 32 extending rearward from the end portion 31 to cover the extending faces 242 . Therefore, the insulated area is extended into inner section of the receiving cavity 12 which protects the contacting portion 23 from being polluted or damaged. The problems addressed above are solved to assure stability of power transmission and safety.
[0038] In addition, the outer surface 321 of the cover portion 32 is coplanar with the contacting surface 231 for assuring the stability of the second contact 7 of the receptacle connector 20 sliding along the outer surface 321 and the contacting surface 231 .
[0039] Please refer to FIGS. 5 and 8 , the additional grounding contact 4 is longitudinal and located below the grounding first contact 2 and together received in the same first contact-receiving passageway 121 with the grounding first contact 2 . The additional grounding contact 4 comprises an additional retaining portion 41 retained in the first insulative housing 2 , an additional connecting portion 42 extending rearward from the additional retaining portion 41 and beyond the first insulative housing 2 , and an additional contacting portion 43 extending forward from the additional retaining portion 41 and forming a contacting end 430 curved upward slightly. The contacting end 430 is located below a front section of the outer surface 321 of the protecting insulator 3 to assure that the additional grounding contact 4 electrically contacts the grounding second contact 7 of the receptacle connector 20 after the grounding first contact 2 . That means, the additional grounding contact 4 and the grounding first contact 2 form electrical connection with the same grounding second contact 7 . Thus, the additional grounding contact 4 is a spare grounding contact to assure an always grounding function even when the grounding first contact 2 is invalid. The grounding function is very important for high-power, high-voltage power connectors.
[0040] Please refer to FIGS. 2 and 7 - 8 , the second insulative housing 6 comprises a second mating face 61 and a plurality of second contact-receiving passageways 60 recessed forward from the second mating face 61 . A protection block 62 protrudes upward from a bottom surface of each second contact-receiving passageway 60 and extends forward from the second mating face 60 into the second contact-receiving passageway 60 a certain distance. In FIGS. 2 and 8 , a latch arm 63 is disposed at a bottom of the second insulative housing 6 for latching with the recess 14 of the first insulative housing 1 . The latch arm 63 comprises a latch section 631 and a pressing section 632 respectively at opposite ends of the latch arm 63 .
[0041] The second contact 7 comprises a flat second retaining portion 71 retained in the second insulative housing 6 , an elastic second contacting portion 72 extending rearward from the second retaining portion 71 and bending upwardly slightly, and a second connecting portion 74 extending forward from the second retaining portion 71 beyond the second insulative housing 6 for electrically connecting with wires (not shown). The second contacting portion 72 comprises an elastic contacting free end 73 with certain deformation ability. In FIG. 8 , when the second contacts 7 are retained in the second insulative housing 6 , the elastic second contacting portions 72 extend beyond upper surfaces of the protection blocks 62 . While, when the plug connector 10 and the receptacle connector 20 mate with each other, the elastic second contacting portions 72 are compressed by the contacting surfaces 231 of the second contacts 2 . The free ends 73 are compressed to be below the upper surfaces of the protection blocks 62 , thus, the second contacts 7 are prevented from being touched or damaged by outside. Correspondingly, the second contacts 7 also comprise three power contacts in triangle relationship in the preferred embodiment of the present invention, a positive second contact, a negative second contact and a grounding second contact 7 located at the top point of the triangle. Of course, the three second contact-receiving passageways 60 are also arranged in triangle relationship with the top second contact-receiving passageway 60 defines an additional contact-receiving passageway 65 at the bottom thereof to protrude through the protection block 62 .
[0042] Please refer to FIG. 8 , when the plug connector 10 mates with the receptacle connector 20 , the second insulative housing 6 is received in the receiving cavity 12 of the first insulative housing 1 . The protection blocks 62 guide the first contacts 2 into the second contact-receiving passageways 60 to form electrical connection with the second contacts 7 . During the mating process, the elastic second contacting portion 72 slides along the outer surface 321 of the cover portion 32 firstly and then slide beyond the cover portion 32 to finally form electrical connection with the contacting surface 231 of the first contacting portion 23 . At the same time, the latch section 631 of the latch arm 63 ′ protrudes into the recess 14 of the first insulative housing 1 to improve the retention force between the plug connector 10 and the receptacle connector 20 . The additional grounding contact 4 protrudes through the additional contact-receiving passageway 65 to contact the grounding second contact 7 after the grounding first contact 2 contacts the grounding second contact 7 .
[0043] When need to separate the plug connector 10 and the receptacle connector 20 , user just needs to press the pressing section 632 of the latch arm 63 downward, the latch section 631 is caused to be separated from the recess 14 . In alternative embodiments, the latch arm 63 also can be disposed on the first insulative housing 1 of the plug connector 10 and the recess 14 is defined in the second insulative housing 6 which also can realize the same purpose. The first contacts 2 can be assembled to or insert-molded with the first insulative housing 1 , and the second contacts 7 also can be assembled to or insert-molded with the second insulative housing 6 . In addition, the additional grounding contact 4 also can be disposed in the second insulative housing 6 of the receptacle connector 20 after a skilled person in the art makes some simple changes to the second insulative housing 6 .
[0044] FIGS. 9-17 disclose a second embodiment of the present invention, a plug connector 10 ′ and a receptacle connector 20 ′ of an electrical connector assembly 100 ′ have similar designs as described in the first embodiment. Hence, only differences will be introduced hereinafter.
[0045] Compared with the plug connector 10 , the plug connector 10 ′ has different first contact structure. The first contacts 2 ′ have different first connecting portions 22 ′ which bend upward (for grounding first contact 2 ′) and downward (for power first contacts 2 ′). The plug connector 10 ′ also comprises a first retainer 5 ′ insert-molded with the first contacts 2 ′ together to form a first contact module. The protecting insulators 3 ′ are firstly insert-molded with the forward ends 24 ′ of the first contacts 2 ′, then the first retainer 5 ′ is insert-molded with the first contacts 2 and together assembled to the first insulative housing 1 ′. The first retainer 5 ′ is assembled to a rear end of the first insulative housing 1 ′ and has a pair of latch means 51 ′ on opposite lateral sides thereof to latch into a pair of through holes 117 ′ of locking means 116 ′ of the first insulative housing 1 ′. An L-shape cutout 52 ′ is recessed downward from a top edge of the first retainer 5 ′ for penetration of the additional grounding contact 4 ′. The first insulative housing 1 ′ defines an additional contact-receiving passageway 122 ′ with a front end thereof communicating with the top first contact-receiving passageway 121 ′.
[0046] The additional grounding contact 4 ′ comprises an additional retaining portion 41 ′, a flat additional contacting portion 43 ′ extending forward from the additional retaining portion 41 ′, and an additional connecting portion 42 ′ extending rearward from the additional retaining portion 41 ′. The additional contacting portion 43 ′ penetrates through the additional contact-receiving passageway 122 ′ to be exposed in the top first contact-receiving passageway 121 ′ together with the grounding first contact 2 ′. A contacting end 430 ′ is stamped with a bump to electrically contact the grounding second contact 7 ′ of the receptacle connector 20 ′. The additional retaining portion 41 ′ comprises a main portion 412 ′ located in a horizontal surface and a rib 411 ′ extending vertically from one edge of the main portion 412 ′ to locate in a vertical surface. A plurality of first barbs 410 ′ and a plurality of second barbs 413 ′ are respectively formed at rear ends of the main portion 412 ′ and the rib 411 ′ to interferentially engage with inner walls of the additional contact-receiving passageways 122 ′ for retaining the additional grounding contact 4 ′ in the first insulative housing 1 ′. The additional connecting portion 42 ′ comprises an L-shape extended section 421 ′ mainly located in a horizontal surface and extending from the additional retaining portion 41 ′, and a connecting section 422 ′ bending upwardly from the extended section 421 ′.
[0047] FIGS. 14-16 disclose the receptacle connector 20 ′. Compared with the receptacle connector 20 , the receptacle connector 20 ′ further comprises a second retainer 9 ′ retaining the second contacts 7 ′ together with the second insulative housing 6 ′. The second retainer 9 ′ is assembled to the second insulative housing 6 ′ after the second contacts 7 ′ are assembled to be received in the second contact-receiving passageways 60 ′ of the second insulative housing 6 ′. The second contacts 7 ′ are sandwiched between the second retainer 9 ′ and the second insulative housing 6 ′ to provide better support to the second connecting portions 74 ′. The second retainer 9 ′ forms a pair of latch means 95 ′ on opposite lateral sides to lock into through holes 66 ′ of a pair of locking means 64 ′ of the second insulative housing 6 ′ to attach the second retainer 9 ′ tightly to the second insulative housing 6 ′. Further, the second contacting portion 71 ′ is of bifurcated shape to improve elasticity thereof.
[0048] Since the plug connector 10 , 10 ′ and the receptacle connector 20 , 20 ′ are high-power power connectors, heat radiation issue must be considered. In the second embodiment of the present invention, heat-radiation structures are designed. The first insulative housing 1 ′ defines a plurality of heat-radiating holes 17 ′ to communicate with at least one first contact-receiving passageway 121 ′, while, the second insulative housing 6 ′ defines a plurality of heat-radiating holes 67 ′ to communicate with at least one second contact-receiving passageway 60 ′. In addition, the second retainer 9 ′ also defines a plurality of heat-radiating passages 97 ′ to communicate with at least one second contact-receiving passageway 60 ′. These heat-radiating structures 17 ′, 67 ′ and 97 ′ communicate the first and second contact-receiving passageways 121 ′, 60 ′ with outside to radiate heat generated by mated first and second contacts 2 ′, 7 ′ to the outside in time to satisfy the heat-radiating requirement.
[0049] 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 full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. For example, the tongue portion is extended in its length or is arranged on a reverse side thereof opposite to the supporting side with other contacts but still holding the contacts with an arrangement indicated by the broad general meaning of the terms in which the appended claims are expressed. | An electrical connector includes an insulative housing, at least one contact and at least one protecting insulator. The insulative housing defines a mating direction, a mating face and a receiving cavity recessed from the mating face along said mating direction. The at least one contact is received in the insulative housing and includes a contacting portion exposed into the receiving cavity, a retaining portion extending from one end of the contacting portion to be interferentially received in the insulative housing, and a forward end extending from the other end of the contacting portion to locate more closely to the mating face of the insulative housing than the contacting portion, and a connecting portion extending from the retaining portion to be exposed beyond the insulative housing. The protecting insulator entirely covers the forward end of the at least one contact. | 28,306 |
RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 09/552,032, filed Apr. 19, 2000, now U.S. Pat. No. 6,711,645, issued Mar. 23, 2004, which is a continuation of U.S. patent application Ser. No. 08/942,317, filed Oct. 1, 1997, now, U.S. Pat. No. 6,134,615, issued Oct. 17, 2000, which claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Application No. 60/046,310, filed May 13, 1997 and entitled “High Performance Network Server System Management Interface.”
PRIORITY CLAIM
The benefit under 35 U.S.C. § 119(e) of U.S. Provisional Application No. 60/046,310, filed May 13, 1997 and entitled “High Performance Network Server System Management Interface,” is hereby claimed.
APPENDIX A
Appendix A, which forms a part of this disclosure, is a list of commonly owned copending U.S. patent applications. Each one of the applications listed in Appendix A is hereby incorporated herein in its entirety by reference thereto.
COPYRIGHT RIGHTS
A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves all copyright rights whatsoever.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to user interfaces for computer systems. More particularly, the present invention relates to implementing a graphical user interface (GUI) to allow for easy and efficient management and maintenance of peripheral devices in a computer network.
2. Description of the Related Technology
As enterprise-class servers, which are central computers in a network that manage common data, become more powerful and more capable, they are also becoming ever more sophisticated and complex. For many companies, these changes lead to concerns over server reliability and manageability, particularly in light of the increasingly critical role of server-based applications. While in the past many systems administrators were comfortable with all of the various components that made up a standards-based network server, today's generation of servers can appear as an incomprehensible, unmanageable black box. Without visibility into the underlying behavior of the system, the administrator must “fly blind.” Too often, the only indicators the network manager has on the relative health of a particular server is whether or not it is running.
It is well-acknowledged that there is a lack of reliability and availability of most standards-based servers. Server downtime, resulting either from hardware or software faults or from regular maintenance, continues to be a significant problem with significant costs. With emerging Internet, intranet and collaborative applications taking on more essential business roles every day, the cost of network server downtime will continue to spiral upward.
While hardware fault tolerance is an important element of an overall high availability architecture, it is only one piece of the puzzle. Studies show that a significant percentage of network server downtime is caused by transient faults in the I/O subsystem. These faults may be due, for example, to the device driver, the device firmware or hardware, which does not properly handle concurrent errors, and often causes servers to crash or hang. The result is hours of downtime per failure while a system administrator discovers the failure, takes some action and manually reboots the server. In many cases, data volumes on hard disk drives become corrupt and must be repaired when the volume is mounted. A dismount-and-mount cycle may result from the lack of “hot pluggability” or “hot plug” in current standards-based servers. Hot plug refers to the addition and swapping of peripheral adapters to an operational computer system. An adapter is simply any peripheral printed circuit board containing microchips, such as a PCI card, that may be removed from or added to a server peripheral device slot. Diagnosing intermittent errors can be a frustrating and time-consuming process. For a system to deliver consistently high availability, it should be resilient to these types of faults.
Existing systems also do not have an interface to control the changing or addition of an adapter. Since any user on a network could be using a particular adapter on the server, system administrators need a software application that controls the flow of communications to an adapter before, during, and after a hot plug operation on an adapter.
Current operating systems do not by themselves provide the support users need to hot add and swap an adapter. System users need software that will freeze and resume the communications of their adapters in a controlled fashion. The software needs to support the hot add of various peripheral adapters such as mass storage and network adapters. Additionally, the software should support adapters that are designed for various bus systems such as Peripheral Component Interconnect, CardBus, Microchannel, Industrial Standard Architecture (ISA), and Extended ISA (EISA). System users also need software to support the hot add and swap of adapters within canisters, which are detachable bus casings for a detachable bus system, and which also provide multiple slots for adapters.
In a typical PC-based server, upon the failure of an adapter, the system must be powered down, the new adapter and adapter driver installed, the server powered back up and the operating system reconfigured. However, various entities have tried to implement the hot plug of these adapters to a fault tolerant computer system. One significant difficulty in designing a hot plug system is protecting the circuitry contained on the adapter from being short-circuited when an adapter is added to a powered system. Typically, an adapter contains edge connectors which are located on one side of the printed circuit board. These edge connectors allow power to transfer from the system bus to the adapter, as well as supplying data paths between the bus and the adapter. These edge connectors fit into a slot on the bus on the computer system. A traditional hardware solution for “hot plug” systems includes increasing the length of at least one ground contact of the adapter, so that the ground contact on the edge connector is the first connector to contact the bus on insertion of the I/O adapter and the last connector to contact the bus on removal of the adapter.
An example of such a solution is described in U.S. Pat. No. 5,210,855 to Bartol.
U.S. Pat. No. 5,579,491 to Jeffries discloses an alternative solution to the hot installation of I/O adapters. Here, each hotly installable adapter is configured with a user actuable initiator to request the hot removal of an adapter. The I/O adapter is first physically connected to a bus on the computer system. Subsequent to such connection, a user toggles a switch on the I/O adapter which sends a signal to the bus controller. The signal indicates to the bus controller that the user has added an I/O adapter. The bus controller then alerts the user through a light emitting diode (LED) whether the adapter can be installed on the bus.
However, the invention disclosed in the Jeffries patent also contains several limitations. It requires the physical modification of the adapter to be hotly installed. Another limitation is that the Jeffries patent does not teach the hot addition of new adapter controllers or bus systems. Moreover, the Jeffries patent requires that before an I/O adapter is removed, another I/O adapter must either be free and spare or free and redundant. Therefore, if there was no free adapter, hot removal of an adapter is impossible until the user added another adapter to the computer system.
A related technology, not to be confused with hot plug systems, is Plug and Play defined by Microsoft® Corporation and PC product vendors. Plug and Play is an architecture that facilitates the integration of PC hardware adapters into systems. Plug and Play adapters are able to identify themselves to the computer system after the user installs the adapter on the bus. Plug and Play adapters are also able to identify the hardware resources that are needed for operation. Once this information is supplied to the operating system, the operating system can load the adapter drivers for the adapter that the user had added while the system was in a non-powered state. However, to date, Plug and Play has only been utilized for the hot docking of a portable computer to an expansion base.
Therefore, a need exists for improvements in server management which can result in continuous operation despite adapter failures. System users should be able to replace failed components, upgrade outdated components, and add new functionality, such as new network interfaces, disk interface adapters and storage, without impacting existing users. Additionally, system users need a process to hot add their legacy adapters, without purchasing new adapters that are specifically designed for hot plug. As system demands grow, organizations must frequently expand, or scale, their computing infrastructure, adding new processing power, memory, mass storage and network adapters. With demand for 24-hour access to critical, server-based information resources, planned system downtime for system service or expansion has become unacceptable.
The improvements of co-ending applications entitled “Hot Add of Devices Software Architecture” (U.S. Pat. No. 6,499,073, issued Dec. 24, 2002) and “Hot Swap of Devices Software Architecture,” (U.S. Pat. No. 6,304,929, issued Oct. 16, 2001), as well as their related applications, all filed on Oct. 1, 1997, adds hot swap and hot add capabilities to server network. The recent availability of hot swap and hot add capabilities requires that a user maintaining the server, usually a server network system administrator, knows or learns the numerous and complicated steps required to swap or add a peripheral device, including how to suspend the device adapters, how to power down and up the correct server slot and/or canister, etc. These steps are more fully disclosed in the co-ending applications referenced above and incorporated herein by reference. In addition, because servers have become very reliable, the system administrator will often be caught in a position of not knowing or having forgotten how to swap or add a peripheral adapter when a server malfunctions or when a new adapter needs to be added. Today's servers do not often malfunction, and the system administrator may add adapters only a few times a year.
Without detailed knowledge of the hot swap and hot add processes, the system administrator will be unable to change out and install peripheral devices. In that case, the entire server system must then be shut down, the peripheral adapter replaced or inserted, and the system restarted. This can result in severe losses to the system users in terms of network downtime and inability to service clients. In addition, it results in a failure to take advantage of the currently available hot swap and hot add technology. However, without an automated step-by-step process from the user's point of view, these results are inevitable.
Therefore, a need exists to automate, as much as possible, the hot swap and hot add processes, so that the benefits of those capabilities in a server are not compromised by insufficient technical knowledge of those processes on the part of the network administrator. Because implementation of the hot add and hot swap processes only depends on (1) which process is necessary (i.e. hot swap or hot add) and (2) which particular server peripheral device slot is concerned, the user should be able to perform these processes knowing such information. The remaining steps in the hot swap and hot add processes may be completely automated. This can allow the necessary hot swapping and hot addition of adapters to be performed quickly and efficiently, by non-expert personnel, while the server is running. In the usual case, it would allow the system administrator to perform a hot swap or a hot add with little or no learning curve.
SUMMARY OF THE INVENTION
The present invention provides a user of a typical client-server or similar system, usually a system administrator, with a simple, understandable user interface that allows the user to both view and transmit basic instructions to perform the steps in a hot plug or similar process in the system. In one embodiment of the invention, the system comprises a computer that includes memory, a module that operates to provide a user interface, and a module that transmits communications and instructions between that user interface and the computer to execute a hot plug process. The user interface may be a graphical user interface, and may comprise a series of screen displays capable of showing and executing the steps of a hot plug process for a peripheral adapter. The hot plug process may be a hot swap process, a hot add process, or other similar process.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing a fault-tolerant computer system which uses one embodiment of the present invention.
FIG. 2 is a diagram showing one embodiment of a server, having eight peripheral adapter slots.
FIG. 3 is a diagram showing another embodiment of a server, having four canisters and sixteen peripheral adapter slots.
FIG. 4 is a logic block diagram illustrating the software modules that may be used to implement the functions of one embodiment of the present invention.
FIG. 5 is a block diagram illustrating the connection between a user interface and the peripheral adapters of a server which can be hot swapped or hot added, including other major parts of the system.
FIG. 6 is a block diagram illustrating one embodiment of the present invention in a network server running the NetWare® operating system.
FIG. 7 is a block diagram illustrating one embodiment of the present invention in a network server running the Windows® NT operating system.
FIG. 8 is a flow diagram illustrating the steps of one embodiment of a hot swap process.
FIG. 9 is a flow diagram illustrating the steps of one embodiment of a hot add process for a server having independent peripheral device slots (NF-9008) and running the NetWare® operating system.
FIG. 10 is a flow diagram illustrating the steps of one embodiment of a hot add process for a server having peripheral device slot canisters (NF-9016) and running the NetWare® operating system.
FIGS. 11 through 18 show the screen displays generated by one embodiment of the graphical user interface for a hot swap process implemented in the NF-9008 server environment.
FIGS. 19 through 26 show the screen displays generated by one embodiment of the graphical user interface for a hot swap process implemented in the NF-9016 server environment.
FIGS. 27 through 32 show the screen displays generated by one embodiment of the graphical user interface for a hot add process implemented in the NF-9008 server environment running the NetWare® operating system.
DETAILED DESCRIPTION OF THE INVENTION
The various features of the invention will be described with reference to a particular software module (referred to as the “Hot Plug PCI Wizard”) and various related components. The Hot Plug PCI Wizard is part of the Maestro Central (“Maestro”) computer program, sold by NetFRAME Systems, Inc. In these drawings, reference numbers are reused, where appropriate, to indicate a correspondence between referenced items. Moreover, although the following detailed description describes particular embodiments of the invention, the invention can be embodied in a multitude of different ways as defined and covered by the claims. Finally, the following detailed description describes embodiments of the invention under the Windows® NT and the NetWare® operating systems. Alternative embodiments of the invention may use other commercial operating systems, such as MacIntosh® OS, OS/2, VMS, DOS, Windows® 3.1/95/98 or UNIX.
In addition, in the following description of the invention, a “module” includes, but is not limited to, software or hardware components which perform certain tasks. Thus, a module may include object-oriented software components, class components, procedures, subroutines, data structures, segments of program code, drivers, firmware, microcode, circuitry, data, tables, arrays, etc. A module also includes all components within the definition of “module” found in RFC 1213, Management Information Base for Network Management of TCP/IP - based Internets: MIB - II , which contains a module defining the basic objects needed to manage a TCP/IP network. Separate RFC documents contain modules defining objects for specific technologies such as Token-Ring interfaces, Open Shortest Path First (OSPF) routing, and Appletalk® networking. Those with ordinary skill in the art will also recognize that a module can be implemented using a wide variety of different software and hardware techniques.
FIG. 1 presents an overview of a computer system in which the invention may be used. One or more servers 10 are used to support one or more clients 12 in a typical client-server network, which is made up of various hardware components, including standard microprocessors. The microprocessors used may be any conventional general purpose single- or multi-chip microprocessor such as a Pentium® processor, a Pentium® Pro processor, a 8051 processor, a MIPS® processor, a Power PC® processor, or an ALPHA® processor. In addition, the microprocessor(s) may be any conventional special purpose microprocessor such as a digital signal processor or a graphics processor. The microprocessor(s) will have conventional address lines, conventional data lines, and one or more conventional control lines.
A user at one of the client 12 monitoring stations uses the Simple Network Management Protocol (SNMP) Manager (Maestro) 14 to obtain information regarding the status of various machines and/or devices in the server, and to send instructions to the server through an SNMP Agent 16 and various other system components as shown. The SNMP serves as a mechanism to provide and transport management information between network components, in order to manage the actual devices in a network. The SNMP was developed almost ten years ago as a standard for internetwork management. It has been widely published and is widely available today.
Maestro 14 at the client uses the SNMP to transmit instructions to the SNMP Agent 16 and SNMP Extension Agent 18 , and vice versa. The SNMP permits interactive network administration via parameter checks and supervision of certain network conditions. SNMP uses a transport protocol stack such as the User Datagram Protocol/Internet Protocol (UDP/IP), Transmission Control Protocol/Internet Protocol (TCP/IP), DECnet (Digital Equipment Corporation network protocol), and others.
Maestro 14 provides the user, including network administrators, with a representation of the state of the target machine and/or devices in the server. It can provide this representation in simple (character-oriented) or graphical form. Maestro 14 herein described is graphical and has been specifically designed for the NF-9000 servers' Management Information Base, or MIB. A MIB is simply a virtual information database containing information necessary to manage devices in the network. The module types that represent management information transferred via the SNMP protocol through the network are gathered in the MIB 20 . Thus, the MIB 20 contains variables that hold status information regarding the server(s) and other devices in the network. Maestro 14 accesses the data in the MIB to send proper instructions to and from the user over the network, using the SNMP. The devices mentioned in the discussion herein include peripheral cards or adapters that may be plugged into receiving slots in the server. The present invention also applies to any device that may be inserted into or removed from a server-that is, “hot pluggable” devices.
The SNMP instructions sent by Maestro 14 reach the SNMP Agent 16 and/or the SNMP Extension Agent 18 at the server end via the network drivers 26 , communication hardware 28 , and network medium. The SNMP Agent 16 and SNMP Extension Agent 18 wait for incoming requests and respond to them using information retrieved from the system services 22 such as device drivers, the Intrapulse 24 firmware, and other components of the operating system. These functions and the software and hardware involved are further described in the co-pending applications entitled “Hot Add of Devices Software Architecture” (U.S. Pat. No. 6,499,073, issued Dec. 24, 2002) and “Hot Swap of Devices Software Architecture,” U.S. Pat. No. 6,304,929, issued Oct. 16, 2001), and their related applications, filed Oct. 1, 1997 and herein incorporated by reference.
The server architecture shown in FIG. 2 represents the NetFRAME Model NF-9008 server. The NF-9008 supports eight (8) peripheral devices, or adapters, through eight (8) peripheral I/O slots 30 . The slots 30 are individually powered and may be accessed directly from the PCI bus 32 and its associated bridge 34 . The server architecture shown in FIG. 3 represents the NetFRAME Model NF-9016 server. The NF-9016 supports sixteen (16) peripheral devices through sixteen (16) peripheral I/O slots 36 . The NF-9016 additionally uses canisters 38 , which are groups of four slots. In the NF-9016 each canister is accessed by the PCI Bus 40 and an associated bridge 42 . Thus, it is necessary to extract a canister to change or add a device to one of the slots inside the canister; therefore, all the other boards in the canister get shut down. In the NF-9008 each peripheral device can be replaced independently of the others.
FIG. 4 shows the explicit modular software implementation of one particular embodiment of the invention. The specific implementation shown and hereinafter described is implemented in the Microsoft® Windows® environment using the C++ programming language. Other software implementations of the invention may be developed by those of ordinary skill in the art.
Upon start-up of Maestro 14 , it creates a module called EnumServer 44 which retrieves information regarding how many network servers are present in the system, and then it creates Server Modules 46 for each of those servers. These and all other “modules” described herein are simply computer software elements that can issue commands to execute functions, including calling other modules, and store data. The use of software modules is well understood in the relevant art.
Thus, because one module is created for each server in the network, the Server Modules 46 provide a physical, one-to-one representation of the server network hardware. The Server Modules 46 transmit and receive information and commands to control their associated server through the MIB Manager Module 48 , which uses the MIB 20 to translate the module variables and send commands to and from the SNMP Module 50 , which can then send and receive logical numerical information over the network 52 to and from the SNMP Agents present at the server. The use of the MIB 20 is disclosed in detail in the copending application entitled “Data Management System Supporting Hot Plug Operations on a Computer,” (U.S. application Ser. No. 08/942,149) as well as its related applications, filed Oct. 1, 1997 and hereby incorporated herein by reference.
The Windows® GUI Module 54 is a standard software module provided in the Microsoft® Windows® 95 and Windows® NT environments. This module implements the basic screen display format in the Microsoft® Windows® environment, which is used by one embodiment of the invention, NetFRAME's Hot Plug PCI Wizard, in creating its graphical user interface (GUI). The screen displays seen by the user upon the user's implementation of either the hot swap or hot add processes, shown herein in FIGS. 11 through 32 , are customized GUI's implemented by the use of subsidiary Custom GUI Modules 56 . For example, Custom GUI 1 Module 56 is used to create the screen display of FIG. 11 , and it contains the data shown in that screen display, including the text, graphics, and select buttons. All of the other customized screen displays are similarly created by an associated Custom GUI Module in the Microsoft® Windows® 95 and Windows® NT environments.
All of the GUI modules for the hot swap/hot add processes are associated with each other, using software pointers, in a manner that will enable them to directly call different screen displays when necessary to create an appropriate sequence of screen displays to implement the hot swap or hot add process. For example, referring to FIG. 11 , the “Back” button on the screen invokes a pointer to the previous custom screen module, the “Next” button invokes a pointer to the custom screen module representing the next step in the underlying process (i.e. hot add or hot swap), the “Cancel” button invokes a pointer to the initial custom screen module for the Hot Plug PCI Wizard, and the “Help” button invokes a pointer to a custom help screen module, which contains information to help answer the user's questions.
Referring again to FIG. 4 , when the Hot Plug PCI Wizard is first accessed by the user within Maestro 14 , it creates the Custom GUI Modules 56 for the hot swap and hot add processes. At that time, Maestro 14 also creates modules 60 , associated with the server modules 46 , representing all of the server canisters, slots, and associated adapters present in the server network. These modules, like the server modules, are able to access and hold data regarding the status of their associated hardware at the server, and issue commands that may be used to manipulate that associated hardware. For example, the Custom GUI module shown in FIG. 15 , from which the user is able to power down a selected slot in a NF-9008 server, first calls the appropriate server Slot Module 60 (here the module for Slot 1 of a one-server NF-9008 network). The Slot Module 60 checks the status of its slotPowerState integer module variable to verify that the slot is powered up, and if so the Slot Module 60 can then issue a “PowerDown” command, through the MIB Manger Module 48 and SNMP Module 50 to the server, where the server hardware receives the instruction through an SNMP agent and executes the instruction to power down the slot. The particular slot is identified by data within the Slot Module 60 , specifically the slotGroupNumber and slotNumber variables for this implementation of the invention. The values associated with these variables would be 1 and 1, respectively, for the first slot on the left, viewing the NF-9008 server from the front, 1 and 2 for the second slot from the left, and so on.
The appropriate canister and adapter modules 60 are called from the Custom GUI Modules 56 , and commands issued therefrom, in an identical manner as will be understood by one of ordinary skill in the art. The specific module variables and data most often used in the hot swap/hot add processes are as follows for the particular modules:
MODULE VARIABLES Canister Module canisterMaximumNumberOfCanisters (=0 for NF-9008) canisterNumber canisterName canisterPowerState Slot Module slotGroupNumber slotNumber slotAdapterPresence slotPowerState Adapter Module adapterNumber adapterName adapterSupportsHotSwapHotAdd adapterState adapterCommand
The module variable names are self-explanatory. Thus, within the Maestro 14 software framework, the Hot Plug PCI Wizard implementation of the present invention is able to use Custom GUI Modules 56 for each screen display that the user sees when performing a hot swap or hot add process. These custom screen displays are easily implemented, and are linked to the server modules 46 , canister, slot, and adapter modules 60 , which are in one-to-one correspondence with the actual server hardware, and which modules (1) provide the user with status information regarding that hardware, and (2) allow the user to easily implement high-level software commands over the network to control the server hardware during the hot swap and hot add processes.
FIG. 5 shows the basic hardware components at the server that respond to instructions generated by the Custom GUI Modules 56 generated by the Hot Plug PCI Wizard software in Maestro 14 . In FIG. 5 , the specific instruction involved deals with hot swapping a peripheral adapter 62 . As explained above, the server operating system could be Windows® NT or NetWare®, including others. First, the GUI 64 accepts a request by the user, such as a system manager or administrator, to perform a hot add or hot swap of a peripheral adapter 62 at the server. The GUI 64 transmits the user's instruction through the operating system 66 to the hot plug system driver 68 and the adapter driver 70 or drivers associated with the peripheral adapter 62 . The hot plug system driver 68 controls the adapter driver 70 for a hot plug operation. The hot plug system driver 68 suspends and resumes the communications between the peripheral adapter 62 and the adapter driver 70 . During the hot add or swap of the peripheral adapter 62 , the hot plug hardware 72 deactivates the power to the peripheral adapter, allowing the user to remove it from the server and replace it with another peripheral adapter. One embodiment of the hot plug hardware 72 may include a network of microcontrollers to carry out this functionality. The peripheral adapter 62 could be any kind of peripheral device, such as a math co-processor, a sound board, or other devices well known in the art.
FIG. 6 is a block diagram illustrating the system components of the NetWare® implementation of one embodiment of the present invention. A configuration manager 74 is responsible for managing all of the peripheral adapters. The configuration manager 74 keeps track of the configuration information for every adapter. The configuration manager 74 also allocates resources for every adapter and initializes each adapter during a hot swap operation. The GUI 96 initiates the requests to the configuration manager 74 to freeze and restart communications to a specified peripheral adapter.
Novell® has created two interfaces for adapter drivers to communicate with the Netware Operating Systems. First, Novell® has provided the Open Datalink Interface (ODI) for network drivers. Second, Novell® has created the Netware Peripheral Architecture (NWPA) for mass storage adapters. Each of these interfaces will be briefly described.
With respect to network device drivers, such as a driver 76 , ODI was created to allow multiple LAN adapters to co-exist on network systems. The ODI specification describes the set of interface and software modules used by hardware vendors to interface with the NetWare® operating system. At the core of the ODI is the link support layer (LSL) 78 . The LSL 78 is the interface between drivers and protocol stacks (not shown). A protocol stack is a layered communication architecture, whereby each layer has a well defined interface.
Novell® has provided a set of support modules that provide the interface to the LSL 78 . These modules are a collection of procedures, macros and structures. These modules are the media support module (MSM) 80 , which contains general functions common to all drivers, and the topology specific modules (TSM) 82 , which provide support for the standardized media types of token ring, Fiber Distributed Datalink Interface (FDDI) and Ethernet. The MSM 80 manages the details of interfacing ODI multi-link interface drivers to the LSL 78 and the NetWare® Operating System. The MSM 80 handles all of the generic initialization and run-time issues common to all drivers. The topology specific module or TSM 82 manages operations that are unique to a specific media type. The Hardware Specific Modules (HSM) 84 are created by each adapter vendor for each type of peripheral adapter. The HSM 84 contains the functionality to initialize, reset and shutdown an adapter. The HSM 84 also handles packet transmission and reception to and from each adapter.
With respect to the mass storage device driver 86 , the NetWare® Peripheral Architecture (NWPA) is a software architecture developed by Novell® which provides an interface for mass storage developers to interface with the NetWare® operating system. The NWPA is divided into two components: a host adapter module (HAM) 90 and a custom device module (CDM) 94 . The HAM 90 is a component that contains information on the host adapter hardware. The CDM 94 is the component of the NWPA that regulates the mass storage adapters. The main purpose of the Filter CDM 94 is to locate each HAM 90 , register for adapter events, and process the I/O suspend and I/O restart requests from the configuration manager 74 .
FIG. 7 is a block diagram illustrating various components of one embodiment of the present invention as implemented under the Windows® NT Operating System (WinNT). A configuration manager 100 controls the process of hot adding and swapping an adapter. An administrative agent 102 initiates requests to the configuration manager 100 and the network of microcontrollers to oversee the process of hot add and swap of an adapter. The administrative agent 102 initiates requests to the configuration manager 100 to suspend and restart the communications of a peripheral adapter. The administrative agent 102 initiates requests to the microcontroller network device driver 104 to turn on and off the power to the appropriate server slots.
The configuration manager 100 controls the communication between each adapter and adapter driver by calling the SCSI port 106 and NDIS 108 . SCSI port and NDIS are interfaces which are exported by the Windows® NT Operating system and which are imported, respectively, into mass storage and network adapter drivers. These interfaces are designed to interact with a miniport 110 which is an instance of an adapter driver. In Windows® NT, each adapter (type of adapter if reentered) will have its own miniport.
The remaining FIGS. 8 through 32 delineate the hot swap and hot add processes as implemented by a user according to one embodiment of the invention, the Hot Plug PCI Wizard software. The Hot Plug PCI Wizard can operate in both the Windows® NT and NetWare® server environments, and the differences between those two implementations are noted herein.
FIG. 8 shows the steps performed in the hot swap process under either the Windows® NT or the NetWare® operating environments. The custom GUI screen displays corresponding to each step in the hot swap process are shown in FIGS. 111 through 26 . Before beginning the hot plug or hot add process, the user first accesses, through a network map window icon or menu, the server management window for the particular server of interest. The user can then enter the Hot Plug PCI Wizard to perform the hot swap or hot add process.
At the first screen, the user performs the first step, Select Operation, to select the operation they wish to perform—either “Hot Swap a PCI card” or “Hot Add a PCI card” (see FIGS. 11 and 19 ). In this case the user selects the former. Upon this selection the Custom GUI Module 56 for that screen retrieves data from the appropriate server module 46 to identify whether the server is a NF-9008, having 8 slots, or a NF-9016, having 4 canisters. The server module 46 obtained this information using the SNMP Module when the user started Maestro 14 .
At the next screen the user selects the specific peripheral device slot where they wish to perform the hot swap operation. At this screen, the display varies depending on whether the server of interest is a Model NF-9008, having 8 independent slots, or NF-9016, having 4 canisters housing 4 slots each. The Custom GUI Module 56 identifies the server by retrieving that information from the server module 46 (see FIG. 4 ), and then incorporates that knowledge to create either the customized screen display of FIG. 12 or FIG. 20 . Thus, if the server is a NF-9008, the user will be displayed FIG. 12 , in which case the user will then select (i.e. single-click) on the slot of interest. If the server is a NF-9016, the user will be displayed FIG. 20 , in which case the user will select the canister first, and then select the appropriate slot within that canister. As noted in FIG. 4 , in either case, the user will only be allowed to select slots that contain adapters, because only those support the hot swapping process. The Custom GUI Module 56 accesses the adapter modules 60 (see FIG. 4 ) to determine which ones (if any) are not hot swappable. This information is contained in the adapter module variable called “adapterSupportsHotSwapHotAdd.”
Again referring to FIG. 8 , the third step in the hot swap process is simply a confirmation screen, which allows the user to see the steps that the software will instruct the server hardware to perform, and prompts the user to continue when ready (see FIGS. 13 and 21 ). Next, the hot swap process begins at the server with the suspension of the requested slot adapters, upon the user activating the “Suspend Adapter(s)” button on the screen (see FIGS. 14 and 22 ). Upon receiving this instruction, the Custom GUI Module for that screen prompts the specified adapter module(s) to send an adapterCommand, “SuspendOperations,” to the MIB Manager Module, which then transfers this message to the SNMP Module. The SNMP Module can then send this SuspendOperations command over the network via the SNMP, to the SNMP Agent. The SNMP Agent then transmits the command to the server hardware, and the appropriate hardware devices are engaged to suspend the affected adapter(s).
Once the adapters are suspended, the SNMP Agent transmits that status information back over the network to the SNMP Module and back through the MIB Manager Module, to the adapter object. The state of the adapterState variable in the adapter module is updated to “Suspended,” and the next Custom GUI module is in communication with this module to recognize that the appropriate adapters have been suspended and the GUI can then move on to the next step in the process. As noted in FIG. 8 , for a server running in the NetWare® environment, only one step is required to both suspend the appropriate adapters and power down the appropriate slot or canister. Thus, the next step for a NetWare® implementation is to actually swap out the intended card.
The next step for a Windows® NT implementation is to power down the appropriate slot, if the server is a NF-9008, or the appropriate canister, if the server is a NF-9016. In the NF-9016, individual slots may not be powered down; instead, the power must be suspended to the entire canister. The screen displays for the power down steps are shown in FIGS. 15 and 23 . Once again, the Custom GUI Module 56 for this step receives the user's confirmation to go ahead with this step, and the module then proceeds to access the slotPowerState or canisterPowerState variable information from the slot or canister module 60 , transmit a “PowerDown” command to the MIB Manager Module 48 and through the network via the SNMP Module 50 . Once the appropriate slot or canister is powered down, the slotPowerState or canisterPowerState receives that information and updates the slot or canister module 60 , and the Custom GUI Module recognized from that information that it may proceed to the next step in the hot swap process.
In either the NetWare® or Windows® NT environment, the next step in the hot swap process is to prompt the user to replace the peripheral card in the selected slot. This allows the user to physically go to the server, find the appropriate slot, and swap out and replace the peripheral card. The screen display for this step, shown in FIGS. 16 and 24 , includes instructions to the user to make sure the LED light at the selected slot is off, and to make sure that the new card is correctly inserted into the slot. Again, once the user has finished this step, the screen display prompts the user to double-click on the “Next” button to proceed to the next step in the hot swap process. For the Windows® NT environment, the nest step is to power back up the affected slot or canister (see FIGS. 17 and 25 ), which the Custom GUI Module 56 for that screen display accomplishes by instructing the slot or canister module 60 to issue a “PowerUp” command to the MIB Manager Module 48 and through the network via the SNMP Module 50 . Once the appropriate slot or canister is powered back up, the slotPowerState or canisterPowerState receives that information and updates the slot or canister module 60 , and the Custom GUI Module recognized from that information that it may proceed to the next, and final, step. As stated above, in the NetWare® environment, this step is not necessary.
The final step in the hot swap process is to restart the adapters that were previously suspended before swapping out the peripheral card. This step is performed by the user from the last screen display, shown in FIGS. 18 and 26 , by the user activating the “Restart Adapter(s)” command. The “Restart Adapter(s)” command prompts the adapter module 60 to issue a “ResumeOperations” command to the MIB Manager Module 48 and through the network via the SNMP Module 50 . Once the user receives confirmation through the adapter module that the state of the adapters (i.e. adapterState) is “Active,” the swapped peripheral card may be used in the server.
FIGS. 9 and 10 show the hot add process steps for the NF-9008 ( FIG. 9 ) and NF-9016 ( FIG. 10 ) servers. The process steps are shown for the NetWare® environment, although the process may also be implemented in the Windows® NT environment as will be understood by one of ordinary skill in the art. The hot add process is very similar to the hot swap process, except that in a hot add process, a peripheral card is inserted in a server slot that previously did not hold a card.
The screen displays for the hot add process for a NF-9008 server are shown in FIGS. 27 through 32 . FIG. 27 shows that the first step in the hot add process is the same screen display as for the hot swap process, except that this time the user selects “Hot Add a PCI card.” When the user selects the hot add option, the Custom GUI Module verifies from the state of the server object that the server is a NF-9008, and then verifies from the adapter and/or slot modules 60 that there is no peripheral card presently in that particular server slot. Once confirmation is received by the Custom GUI Module, in the next step, from the screen display shown in FIG. 28 the user selects the particular slot in which the peripheral card will be added, in a manner similar to the identical step in the hot swap process for the NF-9008 server, described above. The next screen display, shown in FIG. 29 , is simply a confirmation screen, similar to FIG. 13 for the hot swap process, which just allows the user to hit the “Next” button to prompt the next screen. The next step in the hot add process is for the user to go to the server and physically insert the new peripheral card in the slot at the server. The screen display for this step is shown in FIG. 20 . After hitting the “Next” button on the screen display, the user is prompted at the next screen display, shown in FIG. 31 , to hit “Power Up” when ready to power the server slot up with the newly inserted peripheral card. At this step, the Custom GUI Module 54 accesses the appropriate slot module 60 to send a PowerUp command via the MIB Manager Module 48 , the SNMP Module 50 , and the network to the physical server slot, where the command operates to power up the previously inactive slot with the added adapter. Finally, the last user screen in the hot add process instructs the user to make sure to configure the new peripheral card for use. These steps to configure the new card are listed as shown in FIG. 31 , and the configuration process for newly added peripheral cards is readily understood by those of ordinary skill in the art.
For the NF-9016 hot add operation, because the NF-9016 contains its peripheral card slots within canisters, the entire canister must be powered down and then back up in order to add a new card to one of the slots within a canister. For this reason the hot add process for the NF-9016 is nearly identical to the hot swap process for the NF-9016. The process steps in the hot add process are the identical steps implemented in the hot swap process (see FIGS. 8 and 19 – 26 ); the only difference is that when the user goes out to the peripheral card slot, the user only has to insert the new peripheral card rather than first removing an already resident card.
Thus, with respect to each of hot swap and hot add processes herein described and carried out by Maestro 14 , the user is able to successfully complete a hot swap or a hot add of an adapter from the user's computer workstation screen, and is able to do so knowing no information about these processes other than which process is needed, and which particular server peripheral device slot is concerned.
APPENDIX A
Incorporation by Reference of Commonly Owned Applications
The following patent applications, commonly owned and filed
Oct. 1, 1997, are hereby incorporated herein in their
entirety by reference thereto:
application
Title
Ser. No.
“System Architecture for Remote Access
08/942,160
and Control of Environmental
Management”
“Method of Remote Access and Control of
08/942,215
Environmental Management”
“System for Independent Powering of
08/942,410
Diagnostic Processes on a Computer
System”
“Method of Independent Powering of
08/942,320
Diagnostic Processes on a Computer
System”
“Diagnostic and Managing Distributed
08/942,402
Processor System”
“Method for Managing a Distributed
08/942,448
Processor System”
“System for Mapping Environmental
08/942,222
Resources to Memory for Program Access”
“Method for Mapping Environmental
08/942,214
Resources to Memory for Program Access”
“Hot Add of Devices Software
08/942,309
Architecture”
“Method for The Hot Add of Devices”
08/942,306
“Hot Swap of Devices Software
08/942,311
Architecture”
“Method for The Hot Swap of Devices”
08/942,457
“Method for the Hot Add of a Network
08/943,072
Adapter on a System Including a
Dynamically Loaded Adapter Driver”
“Method for the Hot Add of a Mass
08/942,069
Storage Adapter on a System Including a
Statically Loaded Adapter Driver”
“Method for the Hot Add of a Network
08/942,465
Adapter on a System Including a Statically
Loaded Adapter Driver”
“Method for the Hot Add of a Mass
08/962,963
Storage Adapter on a System Including a
Dynamically Loaded Adapter Driver”
“Method for the Hot Swap of a Network
08/943,078
Adapter on a System Including a
Dynamically Loaded Adapter Driver”
“Method for the Hot Swap of a Mass
08/942,336
Storage Adapter on a System Including a
Statically Loaded Adapter Driver”
“Method for the Hot Swap of a Network
08/942,459
Adapter on a System Including a Statically
Loaded Adapter Driver”
“Method for the Hot Swap of a Mass
08/942,458
Storage Adapter on a System Including a
Dynamically Loaded Adapter Driver”
“Method of Performing an Extensive
08/942,463
Diagnostic Test in Conjunction with a
BIOS Test Routine”
“Apparatus for Performing an Extensive
08/942,163
Diagnostic Test in Conjunction with a
BIOS Test Routine”
“Configuration Management Method for
08/941,268
Hot Adding and Hot Replacing Devices”
“Configuration Management System for
08/942,408
Hot Adding and Hot Replacing Devices”
“Apparatus for Interfacing Buses”
08/942,382
“Method for Interfacing Buses”
08/942,413
“Computer Fan Speed Control Device”
08/942,447
“Computer Fan Speed Control Method”
08/942,216
“System for Powering Up and Powering
08/943,076
Down a Server”
“Method of Powering Up and Powering
08/943,077
Down a Server”
“System for Resetting a Server”
08/942,333
“Method of Resetting a Server”
08/942,405
“System for Displaying Flight Recorder”
08/942,070
“Method of Displaying Flight Recorder”
08/942,068
“Synchronous Communication Interface”
08/943,355
“Synchronous Communication Emulation”
08/942,004
“Method for Facilitating the Replacement
08/942,316
or Insertion of Devices in a Computer
System”
“System Management Graphical User
08/943,357
Interface”
“Display of System Information”
08/942,195
“Data Management System Supporting Hot
08/942,129
Plug Operations on a Computer”
“Data Management Method Supporting
08/942,124
Hot Plug Operations on a Computer”
“Alert Configurator and Manager”
08/942,005
“Managing Computer System Alerts”
08/943,356
“Computer Fan Speed Control System”
08/940,301
“Computer Fan Speed Control System
08/941,267
Method”
“Black Box Recorder for Information
08/942,381
System Events”
“Method of Recording Information System
08/942,164
Events”
“Method for Automatically Reporting a
08/942,168
System Failure in a Server”
“System for Automatically Reporting a
08/942,384
System Failure in a Server”
“Expansion of PCI Bus Loading Capacity”
08/942,404
“Method for Expanding PCI Bus Loading
08/942,223
Capacity”
“System for Displaying System Status”
08/942,347
“Method of Displaying System Status”
08/942,071
“Fault Tolerant Computer System”
08/942,194
“Method for Hot Swapping of Network
08/943,044
Components”
“A Method for Communicating a Software
08/942,221
Generated Pulse Waveform Between Two
Servers in a Network”
“A System for Communicating a Software
08/942,409
Generated Pulse Waveform Between Two
Servers in a Network”
“Method for Clustering Software
08/942,318
Applications”
“System for Clustering Software
08/942,411
Applications”
“Method for Automatically Configuring a
08/942,319
Server after Hot Add of a Device”
“System for Automatically Configuring a
08/942,331
Server after Hot Add of a Device”
“Method of Automatically Configuring and
08/942,412
Formatting a Computer System and
Installing Software”
“System for Automatically Configuring
08/941,955
and Formatting a Computer System and
Installing Software”
“Determining Slot Numbers in a
08/942,462
Computer”
“System for Detecting Errors in a Network”
08/942,169
“Method of Detecting Errors in a Network”
08/940,302
“System for Detecting Network Errors”
08/942,407
“Method of Detecting Network Errors”
08/942,573 | A computer software system is disclosed for facilitating a user's replacement or insertion of devices in a computer server network system. The system allows a user to swap or add peripheral devices while the system is running, or in a “hot” condition, with little or no user knowledge of how the system carries out the “hot swap” or “hot add” functions. The system, which consists of a graphical user interface (GUI) and associated computer software modules, allows the user to select a desired peripheral device location within a server, and then provides the modular software structure to automatically execute a series of steps in the hot swap or hot add process. Each step is prompted by the user from the GUI, to invoke commands to instruct a network server through its operating system and hardware to suspend the appropriate device adapters, if necessary, power down the desired device slot or canister, allow the user to replace or insert a new device, and finally restart the adapters and the slot power. The system requires very little detailed input from the user other than identifying the particular peripheral device slot within the server to be maintained. | 62,701 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a nonprovisional application of U.S. provisional patent application “AN AUTOMATIC DIGITAL INFORMATION AND CONTENT SCHEDULING AND BARKERING SYSTEM,” U.S. Serial No. 60/060,111, filed Sep. 26, 1997, having Winston W. Hodge, Robert M. Kamm, Lawrence E. Taylor, David L. Hench, Pierre A. Schuberth, Kang T. Yam and Gary B. Seaton listed as co-inventors and assigned to Alpine Microsystems. The No. 60/060,111 application is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
The present invention relates to distribution of information either through broadcasting transmission over a local or wide area network, e.g., the Internet, or using cable video systems. More particularly, the invention provides a technique, including a method and apparatus, for scheduling distribution of video/audio information so as to maximize viewer ship of the same and, therefore, profits.
High speed networking and mass storage technologies have made possible interactive communication networks which provide consumers with video/audio information. Broadcast, video-on-demand, pay-per view, cable and Internet services are some of the best known services for providing consumers with programming choices ranging from movies to interactive games. FIG. 1 shows the major components of a video on demand service. The video programs, such as movies, are typically stored in one of various formats at a central server 10 . Subscribers 12 submits requests to the server 10 for particular programs over a communications network 14 . The communications network 14 may use any transmission medium, e.g. commercial telephone, cable and satellite networks. Upon receiving a request, server 10 retrieves the video program from mass storage and delivers a data stream, corresponding to the frames of the movie, to the requesting subscriber via distribution network 14 . The data stream is directed to a receiver possessed by the subscriber which converts the data stream into signals necessary for playback and viewing of the movie.
As the number of providers for each of the aforementioned services increases, the bandwidth of the channels available for distributing information decreases. To that end, the prior art is replete with systems and methods of maximizing the revenue generated by a given bandwidth of transmission channels. For example, U.S. Pat. No. 5,758,257 to Herz et al. and U.S. Pat. No. 5,734,720 to Salganicoff each discloses a system and a method for scheduling receipt of desired movies and other forms of data from a network which simultaneously distributes many sources of such data to many customers, as in a cable television system. Customer profiles are developed for the recipient describing how important certain characteristics of the broadcast video program, movie or other data are to each customer. From these profiles, an “agreement matrix” is calculated by comparing the recipient's profiles to the actual profiles of the characteristics of the available video programs, movies or other data.
U.S. Pat. No. 5,594,491 to Hodge et al., assigned to the assignee of the present invention, discloses a system and method for distributing video over ADSL telephone lines. To maximize usage of the bandwidth provided by a system storing the information to be distributed, Hodge et al. advocate implementing a Near-Video-On Demand (NVOD) protocol. The NVOD protocol maps a video program onto disk-drive in an interleaved fashion so that the video program is divided into data packets having a plurality of frames with each pair of adjacent frames corresponding to a pair of frames in a viewing sequence displaced from one another by a predetermined number of frames. Mapping the video frames in this manner renders the system compatible with existing video distribution systems, while maximizing the number of users that may access any given program.
U.S. Pat. No. 5,172,413 to Bradley et al. describes, in pertinent part, use of a central electronic library to store and deliver high-demand entertainment programming to local community electronic libraries that channel the programming to subscribers. Low-demand programming is stored and delivered directly from a local community electronic library located in an area in which there may be a special interest in the programming. In this manner, Bradley et al. maximize access capacity while minimizing investment cost.
U.S. Pat. No. 5,421,031 to De Bey describes, in pertinent part, a video-on-demand system in which a video program disposed on a non-volatile storage device in divided into a plurality of segments. The segments are transmitted to each subscriber as a redundant sequence. The sequence is transmitted in accordance with a scheduling algorithm that ensures all the video segments of the video program are received by the subscriber to enable continuous playback in real-time of the video program. In this manner, the segments typically correspond to a non-contiguous sequence of video frames. The receiver, possessed by the subscriber, includes a buffer having sufficient memory to store a sufficient amount of video segments to ensure the subscriber experiences real-time playback of the video program.
What is needed, however, is a system and method for transmitting programming material so as to maximize the number of viewers of the same.
SUMMARY OF THE INVENTION
The present invention provides a method and apparatus to schedule the distribution of information so as to maximize the viewer ship of the same and, therefore, profits. This is accomplished by dynamically scheduling distribution of information, segments of which are referred to as descriptors that typically correspond to a motion picture program, to be transmitted to an end user having a high probability of viewing the same. A subgroup of the descriptors have a weighting value assigned thereto with the subgroup of the plurality of descriptors having a weighting value differing from the weighting value associated with the remaining descriptors of the subgroup. The weighting value is a function of predetermined parameters associated with the motion picture program, such as revenue generated when released in movie theaters, comments by professional critics and contractual constraints placed upon the distributor by holders of the ownership rights of the motion picture program. Viewing population numbers are assigned to segments of a predetermined period of time, typically the different hours of the day. The descriptors are then scheduled to be transmitted to end users so that the descriptors with the greatest weighting value is transmitted during a segment which has the greatest viewing population number.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified block diagram of a prior art video-on-demand distribution system;
FIG. 2 is a simplified block diagram of a content and management information controller coupled to a plurality of video distribution systems via a communications infrastructure;
FIG. 3 is a detailed block diagram of a video distribution system shown in FIG. 2;
FIG. 4 is a graphical representation of contractual constraints which are quantified and operated on by the content and management information controller shown in FIG. 2;
FIG. 5 is a graph depicting the purchasing rate per day for a given week;
FIG. 6 is a graph depicting the sales of a movie program compared to the number of weeks the movie program has been released; and
FIG. 7 is a graph depicting the average revenue generated by the movie program depicted above in FIG. 6 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 2, a content and management information controller (CAMIC) 11 a super hub controller 13 in data communication with one or more video distribution systems 16 (VS) each of which are in data communication with one or more end users 17 . The super hub controller 13 may be located proximate to one or more of the distribution systems 16 or may be remotely located with respect thereto. To that end, the super hub controller 13 is typically in data communication with the each of the video distribution systems 16 via an existing communication infrastructure 19 , such as the Internet, cable network system, television broadcast network or satellite.
The super hub controller 13 may consist of one or more computers and functions to distribute information to the video distribution systems 16 and control operation of the same, such as content installation, play rule determination, barker channel (advertisements) preparation, accounting, maintenance and the like. Two of the most complicated operations concern content delivery and installation. Specifically, content delivery of any given video program must entertain a plurality of variables to ensure maximum revenue generation by distributing the same. For example, motion picture studios have predetermined requirements that a distributor of a video program must adhere to, such as minimum play times. These motion picture studio requirements are dependent upon many variables such as theater box office receipts, number of viewing times, number of available channels, actual viewing times and the like. The CAMIC 11 is programmed employing standard artificial intelligence and feedback control techniques to facilitate these activities.
In this manner, the CAMIC 11 overcomes many of the difficulties with traditional prior art information distribution systems. Traditionally, video service providers have placed their equipment at cable television and telephone company servers, leaving the operation, management and maintenance to local operators. This required the operators to be responsible for: physical equipment installation & validation; continuing video/multimedia content installation; setting up Barker channel (continuing); setting up Play Rules (continuing); administration of Play Rules (continuing); setting up and maintaining customer data bases (continuing); setting up and maintaining demographic databases; and validating EPG and Billing interfaces. The CAMIC 11 reduces the burden on local operators by providing a centralized automated control of the video servers. As a result, the CAMIC 11 may either supports or replace local operators. This provides added flexibility for information distribution provides by allowing local operators to override the control parameters provided by the CAMIC 11 . Alternatively, the control parameters may be treated as suggestions to simplify the local end operator's system management duties.
The system described will interface with either external or internal Electronic Program Guides (EPGs) and Customer Billing Systems and provide remote or local control of CATV or TELCO Resources at one or many CATV or TELCO Head Ends. With the CAMIC 11 , rapid deployment of operational units to CATV and TELCO head ends may be achieved while minimizing the need for large human organizational support to operate PPV VOD ITV business.
FIG. 3 shows a typical video distribution system 16 with which the present invention may be incorporated. System 16 includes a video server 18 , video storage vault 20 and an access controller 22 . Video server 18 , video storage vault 20 and access controller 22 are in data communication via line 24 . Video server 18 includes a microprocessor 26 which may be incorporated into a personal computer such as a PENTIUM or Motorola 68000 processor. The microprocessor 26 is associated with a memory 28 . Microprocessor 26 is in data communication with one or more disk-drives 30 via a disk read write controller 32 , with each controller 32 uniquely associated with a disk-drive 30 . Although any type of disk drive may be employed, preferably disk drives 30 are single large disk capable of handling at least one video program of 100 minutes in duration. Data from the disk-drive 30 is distributed by network interface circuitry 34 which is in data communication therewith. Interface circuitry 34 includes a multiplexor 36 which distributes data to the requesting subscribers (not shown). Each subscriber typically includes a receiver (not shown) having the circuitry necessary to convert data received from the video server 18 into viewable material.
Video storage vault 20 includes a bulk video storage system such as video juke box 38 . Juke box 38 may comprise of high capacity disks or tapes storing thousands of video programs in encoded, compressed and digitized form. A typical 100 minute movie of VHS quality requires one Gigabyte of storage. However, the amount of storage capacity for a given frame of a movie is dependent upon the quality of the movie. For example, a 100 minute HDTV video requires more the one Gigabyte of storage.
Access controller 22 is in data communication with a memory 40 which typically includes a database identifying authorized subscribers. The interface circuitry 34 is in data communication with the access controller 22 so that access to system 16 by a particular subscriber is restricted unless memory 40 indicates access is authorized. If access is authorized, access controller 22 allows interface circuit to distribute the video programs to the subscriber. Otherwise, access controller 22 denies the subscriber access to data on the system 16 . To maximize the number of users that may access a video program on any given disk-drive 30 , the frames of each video program is mapped thereon in an interleaved fashion. The mapping of the video program on each of disk-drives 30 may be performed prior to a subscriber request, or may be done during a period in which a video program is transferred from the storage vault 20 to the disk-drives 30 , in response to a subscriber's request.
Although the CAMIC 11 may be employed with any type information distribution system, the description contained here will describe implementation of the CAMIC 11 with a pay-per-view(PPV)/video-on-demand (VOD) system. In this implementation, the CAMIC 11 facilitates dynamic content scheduling to optimize revenue generation, as well as barker channel programming. For example, the motion picture studios have constraints (motion play rules MPR) that must be adhered to by distributors of movie programs. A typical MPR requires that movie programs having the greatest revenue in movie theaters be provided a greater percentage of the bandwidth of the video distribution system 16 , than the remaining movies being shown, i.e., movies generating lower revenues in movie theaters. Typically, the movies having lower revenues associated therewith are allocated a minimum amount of bandwidth.
Referring to FIGS. 2 and 4, the contractual constraints presented by MPRs may be envisioned as containing minimum values 40 and maximum values 42 . The area 44 between the minimum 40 and maximum 42 values represents operational latitude for operators. The CAMIC 11 is designed to optimize revenue generation while maintaining operational head end profits while operating within the operational latitude area 44 . This is achieved by dynamically adjusting the scheduling of programming material on the video distribution systems 16 so that, for example, the most profitable films are shown at during a segment of time when the largest view audience is available to perceive the programming information. Conversely, the least profitable movie programs are shown when the fewest numbers of viewer are available, while adhering to the MPRs. Further optimization on limited video distribution systems may be provided by randomizing different events according to a system of “play rules”, as discussed more fully below.
These play rules are evaluated and ranked. There exists one individual play rule value for each movie program or other information to be distributed. These individual Play Rule Values (PRVs) are then ranked and associated with viewing times which are also ranked from minimum to maximum values corresponding to minimum and maximum viewing audiences, respectfully.
The pairing of movies/events with viewing times provides a viewing schedule which can be optimized for expected profitability. Since it is expected that Play Rule Values will change from day to day and week to week, the measurement of Pay Per View (PPV) sales is one of many feedback parameters which will permit parameter optimization, as well as predicted revenue generation by examining the historic revenue generated by theater box office sales. Also, success might be determined by professional critique of the video program material by critics.
Shown below is a sample of movie sales for a period of time. It would be possible to normalize this example in a potential success range with a single value for each movie program from one to ten. This would become an element of the group of parameters making up the Program Rule Values.
TABLE 1
HISTORICAL BOX OFFICE SALES
VARIETY BOX OFFICE
World Wide Sales
VARIETY BOX OFFICE
World Wide Sales
Star Wars (reissue) ™
$645,974,423
Fools Rush In (Sony) ™
$25,526,308
Empire Strikes Back
$459,456,515
Breaking the Waves
$21,502,218
(reissue) ™
(October/ . . .) ™
Ransom (BV) ™
$293,841,038
Private Parts (Par) ™
$18,906,599
101 Dalmatians (BV) ™
$218,369,398
Mother (Par) ™
$18,510,792
Space Jam (WB) ™
$185,699,050
Ridicule
$18,192,910
(CFP/Miramax) ™
Jerry Maguire (Sony) ™
$168,380,416
In Love and War
$17,148,061
(New Line) ™
Star Trek: First Contact
$141,337,397
Jungle 2 Jungle (BV) ™
$16,270,074
(Par) ™
Evita (BV) ™
$132,009,270
That Darn Cat (BV) ™
$15,961,024
Michael (New Line) ™
$101,937,698
Booty Call (Sony) ™
$14,940,756
Scream (Miramax) ™
$90,178,159
Turbulence (MGM) ™
$14,806,390
English Patient
$70,863,872
Marvin's Room
$14,628,339
(Miramax) ™
(Miramax) ™
Mars Attacks (WB) ™
$68,407,743
Ghosts of Mississippi
$13,014,690
(Sony) ™
Dante's Peak (U) ™
$60,618,907
Across the Sea of Time
$12,271,123
(Sony) ™
One Fine Day (20th) ™
$56,730,819
Beautician and the Beast
$10,748,798
(Par) ™
Shine (New Line) ™
$55,863,536
Rosewood (WB) ™
$10,431,502
The Preacher's Wife
$54,210,740
Smilla's Sense of Snow
$7,967,034
(BV) ™
(Fox) ™
Secrets & Lies
$46,736,377
Zeus and Roxanne
$7,098,097
(October/Alliance) ™
(MGM) ™
Absolute Power
$43,140,900
Lost Highway
$6,269,969
(Sony) ™
(October/Malo . . .) ™
Metro (BV) ™
$35,767,377
Gridlock'd (Gramercy) ™
$5,552,507
The Relic (Par) ™
$35,023,090
Sling Blade (Miramax) ™
$5,358,210
Vegas Vacation (WB) ™
$31,328,556
Dangerous Ground
$5,102,151
(New Line) ™
Beverly Hills Ninja
$29,455,486
Hamlet (Sony) ™
$4,149,241
(Sony) ™
Donnie Brasco (Sony) ™
$25,856,141
Meet Wally Sparks
$4,073,582
(Trimark) ™
Fools Rush In (Sony) ™
$25,526,308
The Pest (Sony) ™
$3,407,993
My Fellow Americans
$22,240,513
(WB) ™
Some (but not all) of the elements of the Program Rule Values are: pending real time events, theater box office sales, number of available digital channels, demographic factors, content purchased locally, time of day, day of week, local operator preferences, holidays, time since last play, program duration, avail window and duration, film critics' ratings, and automatically adapting weights for each of these parameters. From these parameters, an electronic spread sheet (matrix) is assembled, shown in Table 2, which automatically computes the PRV for each movie or event. The events are then sorted according to their Play Rule Value which has been scaled in a range from 1 to 10 where 10 is best.
TABLE 2
MOVIE RANKING, INDEPENDENT OF DAY OR TIME
Minimum
Maximum
Theater
Studio
Studio
Gross Sales
Contractual
Weighting
Contractual
Weighting
Real Time
Weighting
“O” in
Weighting
Movie Product Name
Requirements
Values
Requirements
Value
Events
Value
$Millions
Value
When a Man Loves a Woman
803
9
857
5
0
9
50
9
Beverly Hills Cop
501
9
819
5
0
9
42
9
I Love Trouble
708
9
508
5
0
9
31
9
Getting Even With Dad
772
9
813
5
0
9
10
9
Jurassic Park
854
9
735
5
0
9
358
9
Speed
696
9
538
5
0
9
121
9
True Lies
505
9
719
5
0
9
145
9
The Flinstones
907
9
858
5
0
9
130
9
The Client
843
9
859
5
0
9
92
9
Clear and Present Danger
678
9
628
5
0
9
121
9
The Mask
535
9
531
5
0
9
118
9
Natural Born Killers
711
9
821
5
0
9
60
9
Stargate
888
9
333
5
0
9
71
9
Boxing
999
9
888
5
0
9
235
9
Number
of Available
Scaling
Local
Local
Digits(s)
Weighting
Vectors
Weighting
Demographics
Weighting
Contrast
Weighting
Time
Movie Product Name
Channels “C”
Value
“R”
Value
“S”
Value
Purchases “P”
Value
“T”
When a Man Loves a Woman
674
3
945
3
854
3
616
6
626
Beverly Hills Cop
795
3
793
3
624
3
880
6
512
I Love Trouble
759
3
538
3
508
3
653
6
713
Getting Even With Dad
794
3
558
3
832
3
674
6
652
Jurassic Park
782
3
801
3
809
3
577
6
706
Speed
585
3
830
3
408
3
484
6
754
True Lies
812
3
801
3
889
3
804
6
870
The Flinstones
765
3
534
3
853
3
610
6
444
The Client
476
3
852
3
620
3
900
6
677
Clear and Present Danger
967
3
612
3
675
3
887
8
648
The Mask
737
3
805
3
776
3
855
6
752
Natural Born Killers
644
3
687
3
649
3
613
6
508
Stargate
585
3
830
3
409
3
484
6
740
Boxing
987
3
612
3
675
3
687
6
492
Weighting
Weighting
Weighting
Weighting
Local Operator
Movie Product Name
Value
Date “d”
Value
Day “n”
Value
Holiday “h”
Value
Preferences “p”
When a Man Loves a Woman
5
738
2
490
7
457
2
474
Beverly Hills Cop
4
676
6
745
6
611
3
588
I Love Trouble
5
778
5
768
3
755
3
704
Getting Even With Dad
7
662
3
646
3
600
8
516
Jurassic Park
3
523
5
818
8
542
7
907
Speed
8
448
2
741
5
881
4
513
True Lies
5
695
5
473
4
557
3
543
The Flinstones
8
583
3
528
7
503
5
590
The Client
2
633
3
811
4
797
8
817
Clear and Present Danger
5
622
5
825
4
517
7
844
The Mask
2
459
4
483
5
824
2
817
Natural Born Killers
7
534
8
520
5
622
4
682
Stargate
4
867
8
612
5
575
4
567
Boxing
4
585
8
830
5
409
6
484
Cisco
Weighting
Time Since
Weighting
Program
Weighting
& Ebert
Weighting
Rounded
Scaled
Movie Product Name
Value
Last Playing
Value
Duration
Value
Rating
Value
Rank
Rank
When a Man Loves a Woman
6
843
6
709
3
663
1
41283
72
Beverly Hills Cop
5
731
8
818
3
787
1
44804
75
I Love Trouble
5
688
4
924
6
918
1
43994
77
Getting Even With Dad
7
855
5
430
4
668
1
45935
80
Jurassic Park
7
782
8
828
5
880
1
57143
100
Speed
4
514
5
501
2
538
1
40711
75
True Lies
1
717
8
814
7
873
1
45682
84
The Flinstones
7
818
4
465
4
664
1
44824
82
The Client
4
814
5
791
2
839
1
43746
80
Clear and Present Danger
5
513
4
789
7
678
1
45985
84
The Mask
8
663
2
754
8
614
1
40227
74
Natural Born Killers
5
437
3
809
2
778
1
39650
73
Stargate
4
492
4
585
8
830
5
45838
84
Boxing
5
740
4
967
5
612
5
54643
100
In a similar manner, optimum time analysis is developed, and best times by half hour, day and holiday proximity is created and similarly ranked. A mathematical procedure then mates best time with best movie/event ranks, followed by a modest randomizing procedure which reduces distribution of redundant information from occurring thus providing the ability to insert infrequently at optimum times less than optimum content in order to meet contractual play rule requirements.
Inputs to the system for optimum viewing days are based on previous movie sales. The system extrapolates from previous PPV sales and predicts best and worst times for new viewing. This data is available from the system's PPV sales data base.
FIG. 5 depicts best viewing days based upon actual sampled PPV buy rate data from the CAMIC 11 . The higher the value, the better the day. Series 1 through 9 are selected movies. It can be observed that typically, the best PPV days are Friday, Saturday and Sunday. Specifically, Friday gets about 20% of the viewing traffic, Saturday gets 27% and Sunday gets about 20% of the total weekly viewing traffic. From this data the CAMIC 11 may determine the most profitable play schedules.
Further analysis of twenty-one top movies have demonstrated more complex but similar relationships. The analysis of these movies has been simplified to represent the minimum and maximum boundaries for the same 7 day integrated viewing period and the mean values (arithmetic and geometric). Both the arithmetic and mean values have very similar values indicating that the randomly selected 21 sample movies do not have highly variant buy characteristics, thereby facilitating the predictability of viewer ship by days. Similar analyses can be extrapolated for time of day viewing. As shown, two different samples from two different databases produced similar day of week viewing merit values. These values are represented in the Table 3 below as samples A and B and illustrate their very small differences.
TABLE 3
Daily Buy Rates from Two Different Movie Databases
Sample A
Sample B
Difference
Sunday
20%
18%
3%
Monday
10%
9%
2%
Tuesday
7%
7%
0%
Wednesday
6%
8%
−2%
Thursday
8%
9%
−2%
Friday
19%
20%
−1%
Saturday
30%
29%
1%
100%
100%
0%
The third column represents the high correlations between databases.
Time of day viewing merit can be ranked simply into a 3 point scale as shown in Table 4 below. The CAMIC 11 will refine these merit values based upon system feedback: however, these initial estimates provide a good starting point for the time of day merit assessment. The three point scale could be expanded for greater resolution, but this probably isn't necessary for good system operation.
TABLE 4
Figures of Merit Based on Time of Day
AM
PM
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
hour value
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
3
3
3
3
3
2
merit
Poor =
1
OK =
2
Good =
3
When the probabilities of the day of week viewing are applied to the hour of day ranking, the ranking table shown in Table 5 is produced. These hour of week rankings can be sorted and used to meet the requirements which are correspondingly ranked with Movie Play Rule Values. Application of the day of week merit values to the hour of day merit values produces a value of hour per week which can be ranked and matched with movie Play Rule Values; or the process may be extended to determine merit of hours per year. A chart could be produced similar to that depicting weighted merit values of hours per week.
TABLE 5
Figures of Merit Based on Hour and Day of Week
Weighted Hour Per Week Merit Values
24 hour
1
2
3
4
5
6
7
8
9
10
11
12
time
12 hour
1
2
3
4
5
6
7
8
9
10
11
12
time
Sunday
20%
20%
26%
20%
20%
20%
41%
41%
41%
41%
41%
41%
Monday
10%
10%
10%
10%
10%
10%
20%
20%
20%
20%
20%
20%
Tuesday
7%
7%
7%
7%
7%
7%
15%
15%
15%
15%
15%
15%
Wednesday
6%
6%
6%
6%
6%
6%
11%
11%
11%
11%
11%
11%
Thursday
8%
8%
8%
8%
8%
8%
15%
15%
15%
15%
15%
15%
Friday
19%
19%
19%
16%
19%
19%
38%
38%
38%
38%
38%
38%
Saturday
30%
30%
30%
30%
30%
30%
60%
60%
60%
60%
60%
60%
24 hour
13
14
15
16
17
18
19
20
21
22
23
24
time
12 hour
1
2
3
4
5
6
7
8
9
10
11
12
time
Sunday
41%
41%
41%
41%
41%
41%
61%
61%
61%
61%
61%
41%
Monday
20%
20%
20%
20%
20%
20%
31%
31%
31%
31%
31%
20%
Tuesday
15%
15%
15%
15%
15%
15%
22%
22%
22%
22%
22%
15%
Wednesday
11%
11%
11%
11%
11%
11%
17%
17%
17%
17%
17%
11%
Thursday
15%
15%
15%
15%
15%
15%
23%
23%
23%
23%
23%
15%
Friday
38%
38%
38%
38%
38%
38%
57%
57%
57%
57%
57%
38%
Saturday
60%
60%
60%
60%
60%
60%
89%
89%
89%
89%
89%
60%
Referring to FIG. 6, an additional parameter in the Play Rule Value computation is the method to process the data accumulated by the CAMIC 11 sorting specific movie attendance by number of views since release to PPV. It has long been appreciated that movies shown numerous times attract fewer audiences as the time from introduction is elongated. Most movie viewers like to see the movie as soon after release as possible. Statistical analysis of real data have demonstrated this to be the case. The CAMIC 11 continually collects viewing statistics, and processes them many ways as previously demonstrated. Actual data for 30 movies for a period of 13 weeks. FIG. 7 represents the averages for those same movies. This elementary data is then used to predict optimum play rule values in the future.
The evolving (adapting) numbers shown in FIG. 7 are used to predict movie viewing for new releases. The CAMIC 11 learns from old data how to predict new play rule values. When the some of the play rule values suggest heavy positive weighting for a movie, the fact that it has been showing for 3 weeks is an indicator that the play rule value should be attenuated to some extent. The multiplicative weights for this element of this play rule contributing value are automatically adjusted over time using standard feedback techniques.
Therefore, based upon the Expected Movie Sales as a function of time, the CAMIC 11 normalizes the above graphed values to 1 shown in FIG. 6 and then subtracts from the maximum Play Rule Value a value relating to the descending numbers in the graph in FIG. 7 . The de-emphasis value of this element can be seen to drop by about 50% per week until week 5 after which it slowly converges on zero. Optimum content scheduling occurs when the highest ranking content is matched to the highest ranking hours of the week (or year). This is done by sorting content with descending PRVs to hours with descending viewing probabilities, shown in FIG. 8 .
An additional benefit with providing CAMIC 11 is that the scheduling of commercial programming, i.e., barkering channels, may be optimized to maximize the association of the commercial programming with the product, e.g., movie program, being advertised. For example, if several movies are starting at the same time soon, it may be desirable to present the Barker for the movie with the highest play rule value immediately prior to the movie preceded by the Barker for the movie with the next highest play rule value, and so forth.
Play Rule Values (PRVs) for either a movie or a barker channel programming are computed from a table driven algorithm as follows: PRV = V { Cmin < ∑ i = 1 m PRV = f ( D , C , K , S , P , t , d , n , h , p ) / N < Cmax }
Where “N” is a normalizing factor by which PRV is normalized in a range from 1 to 10, with 10 representing the movie with maximum plays and 1 representing movies with minimum plays and “m” is number of movies Cmin and Cmax represent motion picture studios contractual requirements, D represents theater gross sales, C represents number of available digital channels, i.e., bandwidth; K represents scaling factors; S represents local geographic parameters, e.g., weather conditions; P represents, local demographic parameters, e.g., the type of programming material typically purchased; t represents time of day; d represents the date of a calendar year; n represents either the day of a week or of a year; h represents a holiday; p represents local operator preferences or time since programming material was distributed.
The PRV parameters represent a table from which the PRV values are computed. The table is then sorted according to PRV and the one to ten value directs the systems' presentation sequence. The PRV value is within the studio contract ranges between Cmin and Cmax.
The Barker algorithm employs the PRV as an entry in its table to schedule the type of trailers and the time the trailers are to be shown. The barker channel may have 2 or more hours of clips ranging from a few seconds to a few minutes, describing upcoming recorded or real time attractions.
Part of the barker table is a listing of at what times the movies and other content plays. This table is a logical table, and is used to determine which barker clips should play and when, on a dynamic basis. Further, there will be at least one Barker trailer for each movie or other event, but there will likely be 3 Barker trailers for each event: one long trailer, one medium trailer and one short trailer. These different length trailers will be used to maximum advantage. For example, when 4 movies are about to start in a very short time, it will be applicable to use short trailers. When movies are 30 to 60 minutes from starting, the longer trailers can be employed.
The Barker scheduling process will read the Program Schedule to determine placement of the “call to action” trailers. It will also note the next scheduled start time of the feature to which each trailer refers. This information could be used to generate a caption overlay to act as a countdown clock.
The subsequent table illustrates how 30 second and 1 minute trailers could be assembled together in real time to provide content with a high PRV with a higher advertising rate than content with a low PRV. | A method and apparatus for scheduling the distribution of information so as to maximize the viewer ship of the same and, therefore, profits. Dynamic scheduling of distribution of subportions of the information, referred to as descriptors that typically correspond to a motion picture program, is achieved so that the subportions may be transmitted to end users having a high probability of perceiving the same. A subgroup of the descriptors have a weighting value assigned thereto with said subgroup of said plurality of descriptors having a weighting value differing from the weighting value associated with the remaining descriptors of said subgroup. The weighting value is a function of predetermined parameters associated with said motion picture program, such as revenue generated when released in movie theaters, comments by professional critics and contractual constraints placed upon the distributor by holders of the ownership rights of the motion picture program. Viewing population numbers are assigned to segments of a predetermined period of time, typically the different hours of the day. The descriptors are then scheduled to be transmitted to end users so that the descriptors with the greatest weighting value is transmitted during a segment which has the greatest viewing population number. | 63,945 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an installation and a method for producing cold and/or heat by a sorption system.
2. Description of the Related Art
When the production of energy is not located near the place where the energy is required, it is necessary to provide for transport means. The most widespread energy transport means are the electricity distribution grids. It is nonetheless well-known on the one hand that the conversion efficiency of a primary energy into electricity barely exceeds 50%, and that furthermore, the transport of the electricity is accompanied by losses of about 15%. It is also known how to transport energy in thermal form for the distribution of cold or heat, particularly in urban or industrial networks, using heat transfer fluids (such as water or steam for example) which exchange heat with the medium to be heated or to be cooled. In most cases, these types of exchange involve an exchange of sensible heat or latent heat, which causes the recirculation of large fluid flows and consequently heat losses associated with the high or low temperature of the heat transfer fluid, as well as a high consumption of pumping energy.
Installations for producing heat or cold are known based on thermochemical systems, which employ reversible processes between a gas, called the working gas, and a liquid or a solid. In these systems, the combination step between the gas and the liquid or the solid (absorption of the gas by the liquid, adsorption of the gas on the solid, reaction between the gas and the solid) is exothermic, and the reverse step is endothermic. A large number of reactors and methods based on these principles have been described. They are described in particular in U.S. Pat. No. 4,531,374 (Alefeld) which describes many variants of a device for producing cold or heat based on reversible reactions. These devices operate by reversible absorption of a working gas by a liquid in two working gas circulation circuits operating at two or three pressure levels. Owing to the various operating modes described, the use of such a reactor requires the circulation of the liquid absorbent between one of the reactors of one of the working gas circulation circuits and one of the reactors of the other circuit. This circulation of large quantities of liquid demands pumping means which consume non-negligible quantities of energy, and considerable insulation means to prevent heat losses during the transport of the liquid. The energy supplied to the device during a complete operating cycle is added sometimes to the evaporator supplying the working gas, sometimes to the reactor containing the liquid enriched in gas, in order to liberate the gas, said input therefore taking place at temperatures higher than the gas evaporation temperature and consequently incurring a higher cost. Furthermore, U.S. Pat. No. 4,523,635 and U.S. Pat. No. 4,623,018 describe systems which operate by reversible insertion of hydrogen in hydrides. The systems comprise at least two operating units each consisting of two reactors containing a hydride and connected by a pipe for circulating hydrogen. According to U.S. Pat. No. 4,523,635, during an operating cycle, hydrogen is liberated from a first hydride by adding heat at high temperature to the reactor of one operating unit which contains the hydride whereof the equilibrium temperature is the higher. In the operating mode described in U.S. Pat. No. 4,623,018, each cycle includes at least one step during which heat is added by an external source to a “high temperature” reactor of one of the operating units.
SUMMARY OF THE INVENTION
The present invention is aimed at supplying a method and an installation for producing cold and/or heat at their place of use, using one or a plurality of thermal energy sources, thereby avoiding the transportation of liquid or solid material, and by supplying the energy necessary for the operation of the installation at a relatively low temperature.
An installation for producing cold and/or heat according to the present invention comprises an HP assembly comprising reactors R 1 and R′ 1 , an LP assembly comprising reactors R 3 and R′ 3 and possibly an IP assembly comprising reactors R 2 and R′ 2 . In the rest of the text, R i denotes any one of the reactors R 1 ,R 2 and R 3 , and R′ i denotes any one of the reactors R′ 1 , R′ 2 and R′ 3 . The installation is characterized in that:
each reactor R i is the seat of a reversible sorption alternatively producing and consuming the gas G i , each reactor R′ i is the seat of a reversible process alternatively producing and consuming the gas G i , the reactants in the reactors are selected so that, at a given pressure: the sorption equilibrium temperature in the reactor R i of an assembly is higher than the equilibrium temperature of the reversible process in the reactor R′ i of the same assembly, the sorption equilibrium temperature in the reactor R 1 is lower than that in R 3 , and, if applicable, the sorption equilibrium temperature in R 2 is between the equilibrium temperatures in R 1 and R 3 , the reactors R i and R′ i of an assembly are equipped with means for exchanging the gas G i , the reactors R i are equipped with means for exchanging heat with each other, the reactors are isolated from atmospheric pressure.
A Clapeyron diagram shows the equilibrium curve (pressure P, temperature T) of a reversible process, generally in the form lnP=f(−1/T). The theoretical equilibrium curve is a line for a monovariant process such as a chemical reaction or a liquid/gas phase change. The equilibrium curve is a network of isosteres for the bivariant processes such as the adsorption of a gas on a solid or the absorption of a gas in a liquid, because the equilibrium point varies as a function of the concentration of gas in the solid or the liquid. Owing to the representation used, a curve corresponding to a given reversible process situated further to the left in a Clapeyron diagram means that, at a given pressure, the transformation temperature is lower than that of a reversible process whereof the equilibrium curve is situated further to the right in the diagram. In a given assembly of the installation of the invention, the temperature in the reactor R′ i is consequently lower than the temperature in the reactor R i when the two reactors are caused to communicate by opening the gas transfer means, that is, when the reactors are at the same pressure.
In an installation according to the invention, the reactors R 1 ,R′ 1 of the HP assembly consequently operate in a range of (pressure, temperature) (PT) 1 located at a roughly higher level than the range (PT) 3 of the LP assembly. The IP assembly, when the installation comprises three assemblies, operates in a range (PT) 2 intermediate between (PT) 1 and (PT) 3 .
The reversible processes in the reactors R′ i can be selected among the liquid/gas phase changes and among the reversible sorptions such as reversible chemical reactions, adsorptions of a gas on a solid, absorptions of a gas by a liquid, the formation of clathrate hydrates.
Each reactor R i is the seat of a reversible sorption such as a chemical reaction, an adsorption of a gas by a solid, an absorption of a gas by a liquid, or the formation of clathrate hydrates.
A liquid/gas phase change Li⇄G i is exothermic in the condensation direction and endothermic in the evaporation direction. A reversible sorption between a liquid or solid sorbent and a gas, which can be written Bi+G i ⇄(Bi,G i ), is exothermic in the sorption direction S i and endothermic in the desorption direction D i .
Numerous combinations are possible based on these reversible processes, and they serve to reach desired temperatures for producing useful cold or useful heat.
For example, in the installations comprising two HP and LP assemblies, an identical reversible process or different processes can be used in the reactors R′ i . If the processes in the two reactors R′ i liberate the same gas, the sorbents in the reactors R i must be different. If the processes in the reactors R′i liberate different gases, the sorbents in the reactors R i may be identical or different.
Similarly, in the installations comprising three HP, LP and IP assemblies, reversible processes liberating the same gas G or liberating different gases G i can be used in the reactors R′ i . The reactors R i associated with reactors R′ i which liberate the same gas must contain different sorbents. When the reactors R′ i liberate different gases, the reactors R i associated with them may contain identical or different sorbents.
In a specific embodiment, the reactors R′ i are the seat of a liquid/gas phase change liberating the same gas and each reactor R i is the seat of a reversible sorption between said gas and a different liquid or solid.
In another embodiment, each reactor R′ i is the seat of a liquid/gas phase change producing a different gas and each reactor is the seat of a sorption involving a different solid or liquid.
The method according to the present invention for producing cold and/or heat in a given place comprises a succession of reversible processes between a gas and a liquid or a solid. It is characterized in that:
it is put into practice in an installation which comprises an HP assembly comprising reactors R 1 and R′ 1 , an LP assembly comprising reactors R 3 and R′ 3 and possibly an IP assembly comprising reactors R 2 and R′ 2 , in which installation:
each reactor R i is the seat of a reversible sorption alternatively producing and consuming the gas G i , each reactor R′ i is the seat of a reversible process alternatively producing and consuming the gas G i , the respective sorbents and gases in the reactors are selected so that, at a given pressure: the sorption equilibrium temperature in the reactor R i of an assembly is higher than the equilibrium temperature of the reversible process in the reactor R′ i of the same assembly, the sorption equilibrium temperature in the reactor R 1 is lower than that in R 3 , and, if applicable, the sorption equilibrium temperature in R 2 is between the equilibrium temperatures in R 1 and R 3 , the reactors R i and R′ i of an assembly are equipped with means for exchanging the gas G i , the reactors R i are equipped with means for exchanging heat with each other, the reactors are isolated from atmospheric pressure,
the thermal energy sources necessary for the operation of the installation supply the reactors R′ i .
More specifically, the method for producing cold or heat according to the invention comprises:
a preliminary step in which the gas exchange means between two reactors of an assembly are closed and the respective sorbents and gases are placed at ordinary temperature in the reactors so that the reactor R 1 of the HP assembly contains the sorbent in a form rich in gas (B 1 ,G 1 ), the reactor R′ 1 is in a state to consume the gas G 1 , the reactor R 3 of the LP assembly contains the sorbent in a form poor in gas B 3 and the corresponding reactor R′ 3 is in a state to supply gas G 3 , a step a) of the production of cold and or heat, during which the gas exchange means are opened between the reactors R 3 and R′ 3 on the one hand, the reactors R 1 and R′ 1 , and if applicable between the reactors R 2 and R′ 2 , possibly after having raised the reactor R′ 3 and if applicable R′ 2 to a temperature higher than the normal temperature by the input of heat energy, a step b) of regeneration during which the gas exchange means are opened between the reactors R 3 and R′ 3 on the one hand, the reactors R 1 and R′ 1 , and if applicable between the reactors R 2 and R′ 2 , after having raised the reactor R′ 1 and if applicable R′ 2 to a temperature higher than the normal temperature by the input of heat energy.
At the end of the regeneration step, the installation is again in a state to produce cold or heat. It then suffices to close the gas exchange means between the reactors of the same level, to maintain the installation in this state as long as necessary. If it is again desired to produce cold or heat, it suffices to repeat step a) of production described here above, followed by the regeneration step b), and so forth as required.
In a specific embodiment, essentially aimed to produce cold, the method of the invention is characterized in that:
the respective gases and sorbents in the LP assembly (or the LP and IP assemblies) are selected so that, at the respective pressure which occurs in R′ 3 (or in R′ 3 and R′ 2 ) after opening the gas exchange means in the reactors, the equilibrium temperature of the reversible process in R′ 3 (or in R′ 3 and in R′ 2 ) corresponds to the temperature at which the production of cold is desired, during step a) of production, the gas exchange means are opened between the reactors without a prior input of heat energy to the reactor R′ 3 (or to the reactors R′ 3 and R′ 2 ).
In an installation according to the invention used to produce cold, the cold production temperature is determined by the temperature at which the gas G i is liberated in the reactor R′ i of the LP assembly or of the LP and IP assemblies which are in the lowest ranges of (pressure, temperature). The reversible processes in the two reactors of an LP assembly (and possibly of the IP assembly) are selected so that the simple communication of the reactors R i and R′ i of the same assembly causes the spontaneous endothermic liberation of the gas G i in R′ i and the sorption phase in R i , with the withdrawal of the heat energy necessary from the ambient medium, that is the production of cold at the level of R′ i . The spontaneous withdrawal of heat energy from the ambient medium results in the production of cold in the reactor R′ 3 and if applicable in the reactor R′ 2 during step a). Then, to regenerate the installation during step b), heat energy is added via the reactor R′ i of the assembly having the highest range (pressure temperature), and possibly of the assembly having the intermediate range (pressure, temperature), before opening the gas exchange means between the reactors R i and R′ i . Simultaneously, the installation restores heat energy during each of the steps, to the reactors R′ i which are not involved by the introduction of energy and which are accordingly at intermediate temperatures between the low cold production temperatures and the high regeneration temperatures of the installation. If these intermediate temperatures are useful temperatures, the installation can be used to produce cold and heat simultaneously.
In an installation according to the invention comprising two HP and LP assemblies, the cold is produced at the temperature at which the gas is liberated in the reactor R′ 3 of the LP assembly. The method is put into practice in the following conditions:
during a preliminary step,
the gas transfer means between R 1 and R′ 1 on the one hand, between R 3 and R′ 3 on the other are closed, the respective sorbents and gases are introduced into the reactors so that the reactor R 1 of the HP assembly contains the sorbent in a form rich in gas (B 1 ,G 2 ), the reactor R′ 1 is in a state to consume the gas G 1 , the reactor R 3 of the LP assembly contains the sorbent in a form poor in gas B 3 and the corresponding reactor R′ 3 is in a state to supply gas G 3 , the respective gases and sorbents in the LP assembly are selected so that, at the respective pressure which occurs in R′ 3 after opening the gas exchange means, the equilibrium temperature of the reversible process in R′ 3 corresponds to the temperature at which the production of cold is desired;
during step a) which is the cold production step, the gas transfer means are opened between the reactors R 3 and R′ 3 on the one hand and between the reactors R 1 and R′ 1 on the other, thereby causing the spontaneous liberation of gas G 3 in R′ 3 , the exothermic sorption of G 3 with the sorbent B 3 in R 3 , the endothermic desorption of the sorbent rich in gas (B 1 ,G 1 ) in R 1 , the exothermic consumption of the gas G 1 in R′ 1 ; during step b) which is the regeneration step, heat energy is added to R′ 1 to raise it to a temperature higher than the ambient temperature, the gas transfer means are opened between the reactors R 3 and R′ 3 on the one hand and between the reactors R 1 and R′ 1 on the other, thereby causing the liberation of gas G 1 in R′ 1 , the exothermic sorption of G 1 with the sorbent B 1 in R 1 , the endothermic desorption of the sorbent rich in gas (B 3 ,G 3 ) in R 3 , the exothermic consumption of the gas G 3 in R′ 3 .
At the end of step b), the installation is again in a state to produce cold. It suffices to connect the reactors R 3 and R′ 3 of the LP assembly. In such an installation, the cold is produced in R′ 3 and regeneration is achieved by R′ 1 . Only the reactor R′ 3 , the seat of cold production, is necessarily located at the place where the production of cold is required. The reactor R′ 1 supplied with heat energy during the regeneration of the installation is located at the place where the heat energy is available and the other reactors are located at any appropriate place, that is, at any distance from the place of cold production. It is therefore possible to produce cold in a given place from a heat energy source located elsewhere, by the simple circulation of gas at any temperature, without the transport of hot or cold liquid or solid. All the difficulties connected with the actual transport of solids or gases are thereby eliminated, as well as the heat losses.
The operation of an installation with two assemblies as described here above is similar, whether the respective gases G 1 and G 3 are identical or different.
In an installation comprising three assemblies, several cold production modes can be considered. The cold can be produced at two different temperatures during the same production cycle. The cold can be produced at a given temperature in two successive phases during the production step a). The cold can also be produced at a given temperature in a single phase during the step a), the regeneration step then taking place in two phases.
For the production of cold at two different temperatures, the method is put into practice in an installation which comprises three HP, LP and IP assemblies respectively comprising the reactors R 1 ,R′ 1 , R 3 ,R′ 3 and R 2 ,R′ 2 , in the following conditions:
during a preliminary step,
the gas exchange means are closed between the reactors R 1 ,R′ 1 , R 3 ,R′ 3 and R 2 ,R′ 2 , the respective sorbents and gases are introduced into the reactors so that the reactor R 1 of the HP assembly contains the sorbent in a form rich in gas (B 1 ,G 1 ), the reactor R′ 1 is in a state to consume the gas G 1 , the reactors R 3 and R 2 of the LP and IP assemblies contain their sorbent in a form poor in gas, respectively B 3 and B 2 , and the reactors R′ 3 and R′ 2 are in a state to supply the respective gases G 3 and G 2 , the respective gases and sorbents in the LP and IP assemblies are selected so that, at the respective pressures which occur in R′ 3 and R′ 2 after opening the gas exchange means, the equilibrium temperatures of the respective reversible processes in R′ 2 and R′ 3 correspond to the temperatures at which the production of cold is desired;
during step a) the gas exchange means are opened between the reactors R 1 ,R′ 1 , R 3 ,R′ 3 and R 2 ,R′ 2 , thereby causing the spontaneous liberation of G 3 in R′ 3 and of G 2 in R′ 2 , the exothermic sorption of G 3 with the sorbent B 3 in R 3 , the exothermic sorption of G 2 with the sorbent B 2 in R 2 , the endothermic desorption of the sorbent rich in gas (B 1 ,G 1 ) in R 1 , the exothermic consumption of the gas G 1 in R′ 1 ; during step b), heat energy is added to R′ 1 , the gas exchange means are then opened between the reactors R 1 ,R′ 1 ,R 3 ,R′ 3 and R 2 ,R′ 2 , thereby causing the liberation of gas G 1 in R′ 1 , the exothermic sorption of G 1 with the sorbent B 1 in R 1 , the endothermic desorption of the sorbent rich in gas (B 3 ,G 3 ) in R 3 , the exothermic consumption of the gas G 3 in R′ 3 , the endothermic desorption of the sorbent rich in gas (B 2 , 2 ) in R 2 , and the exothermic consumption of the gas G 2 in R′ 2 .
During step a), the production of cold is observed in R′ 3 and R′ 2 . During step b), the installation is regenerated by supplying heat energy to R′ 1 . Cold can thereby be produced by the simple circulation of gas at an ordinary temperature, at the place where R′ 3 and R′ 2 are located, the other portions of the installation and the heat source supplying R′ 1 being situated elsewhere.
For the production of cold in two phases during the cold production step, the method is put into practice in an installation which comprises three HP, LP and IP assemblies respectively comprising the reactors R 1 ,R′ 1 , R 3 ,R′ 3 and R 2 ,R′ 2 , in the following conditions:
during a preliminary step,
the gas exchange means are closed between the reactors R 1 ,R′ 1 , R 3 ,R′ 3 and R 2 ,R′ 2 , the respective sorbents and gases selected are introduced in the reactors so that the reactors R 1 and R 2 contain their respective sorbent in a form rich in gas (B 1 ,G 1 ) and (B 2 ,G 2 ), the reactors R′ 1 and R′ 2 are in a state to consume the respective gas G 1 and G 2 , the reactor R 3 contains the sorbent in a form poor in gas B 3 , and the reactor R′ 3 is in a state to supply the gas;
during step a) in a first phase, the gas exchange means are opened between the reactors R 3 , R′ 3 on the one hand and the reactors R 2 ,R′ 2 on the other, thereby causing the spontaneous liberation of G 3 in R′ 3 with the production of cold, the exothermic sorption of G 3 with the sorbent B 3 in R 3 , the endothermic desorption of the sorbent rich in gas (B 2 ,G 2 ) in R 2 , the exothermic consumption of G 2 in R′ 2 ; in a second phase, the gas exchange means are opened between the reactors R 1 ,R′ 1 on the one hand and the reactors R 2 ,R′ 2 on the other, thereby causing the spontaneous liberation of G 2 in R′ 2 with the production of cold, the exothermic sorption of G 2 with the sorbent B 2 in R 2 , the endothermic desorption of the sorbent rich in gas (B 1 ,G 1 ) in R 1 , the exothermic consumption of the gas G 1 in R′ 1 ; during step b), heat energy is added to R′ 1 to raise it to a temperature higher than the normal temperature, the gas transfer means are then opened between the reactors R 1 ,R′ 1 on the one hand and the reactors R 3 ,R′ 3 on the other, thereby causing the liberation of gas G 1 , the exothermic sorption of G 1 with the sorbent B 1 in R 1 , the endothermic desorption of the sorbent rich in gas (B 3 ,G 3 ) in R 3 , and the exothermic consumption of the gas G 3 in R′ 3 .
At the end of the step b), the installation is again in a state to produce cold. The simple contacting of R′ 3 and R 3 serves to restart the process. In this specific case, the reactors R′ 3 and R′ 2 can be located at the same place or in different places, depending on whether cold is to be produced in one or two places, using a heat source supplying the reactor R′ 1 located elsewhere. All or some of the gases may be identical in the installation. If the reactors R′ 3 and R′ 2 are the seat of the same reversible process involving the same gas, the cold is produced at the same temperature in the two phases of the production phase. This embodiment enables an increase in the cold production efficiency.
For the production of cold in a phase during the cold production step, the method is put into practice in an installation which comprises three HP, LP and IP assemblies respectively comprising the reactors R 1 ,R′ 1 , R 3 ,R′ 3 and R 2 ,R′ 2 ,in the following conditions:
during a preliminary step,
the gas exchange means are closed between the reactors R 1 ,R′ 1 , R 3 ,R′ 3 and R 2 ,R′ 2 , the respective sorbents and gases are introduced into the reactors R i and the reactors R′ i and selected so that the reactors R 1 and R 2 contain their respective sorbent in a form rich in gas (B 1 ,G 1 ) and (B 2 ,G 2 ), the reactors R′ 1 and R′ 2 are in a state to consume the respective gas G 1 and G 2 , the reactor R 3 contains the sorbent in a form poor in gas B 3 , and the reactor R′ 3 is in a state to supply the gas;
during step a) the gas transfer means are opened between the reactors R 3 ,R′ 3 on the one hand and the reactors R 1 ,R′ 1 on the other, thereby causing the spontaneous liberation of G 3 in R′ 3 , the exothermic sorption of G 3 with the sorbent B 3 in R 3 , the endothermic desorption of the sorbent rich in gas (B 1 ,G 1 ) in R 1 , the exothermic consumption of the gas G 1 in R′ 1 ; during step b), in a first phase, heat energy is added to R′ 1 and the reactors R 1 ,R′ 1 on the one hand and the reactors R 2 ,R′ 2 on the other are connected, thereby causing the spontaneous liberation of G 1 , the exothermic sorption of G 1 with the sorbent B 1 in R 1 , the endothermic desorption of the sorbent rich in gas (B 2 ,G 2 ) in R 2 , and the exothermic consumption of the gas G 2 in R′ 2 ; in a second phase, heat energy is added to R′ 2 , the reactors R 2 ,R′ 2 on the one hand and the reactors R 3 ,R′ 3 on the other are connected, thereby causing the liberation of gas G 2 , the exothermic sorption of G 2 with the sorbent B 2 in R 2 , the endothermic desorption of the sorbent rich in gas (B 3 ,G 3 ) in R 3 , and the exothermic consumption of the gas G 3 in R′ 3 .
This embodiment, in which the cold is produced in the reactor R′ 3 using energy sources supplying the reactors R′ 1 and R′ 2 placed elsewhere, serves to increase the cold production capacity.
It therefore appears that, in all the embodiments of the method of the invention for producing cold, the cold is produced in the reactor R′ 3 in an installation with two assemblies which is regenerated by the input of heat to the reactor R′ 1 , or in the reactor R′ 3 (or the reactors R′ 3 and R′ 2 ) in an installation with three assemblies which is regenerated by the input of heat in the reactors R′ 2 and R′ 1 (or in the reactor R′ 1 ). In all cases, the heat source or sources used for the regeneration of the installation may be placed at a certain distance from the place where the cold is to be produced. Cold can thereby be produced at a given place, using an energy source placed elsewhere, by the simple transport of the working gas at ambient temperature. This characteristic, combined with the input of heat to the low temperature reactors of an assembly, therefore allows the remote production of cold and in a more economical manner than in the installations of the prior art.
In another embodiment, essentially aimed to produce heat at a given place of use, at a temperature higher than the temperature of a heat energy source, the method of the invention is characterized in that, during step a) of production, heat energy is added to the installation by the reactor R′ 3 , and possibly by the reactor R′ 2 , before opening the gas exchange means between the reactors R 3 and R′ 3 , and possibly between the reactors R 2 and R′ 2 .
In an installation according to the invention aimed to produce heat at a temperature higher than that of the energy source employed, during step a) of production, heat energy is supplied to the installation by the reactor R′ 3 of the LP assembly or by the reactors R′ 3 and R′ 2 of the LP and IP assemblies, and heat is recovered in the reactor R′ 1 of the HP assembly or by the reactors R′ 1 and R′ 2 of the HP and IP assemblies, that is, at the elevated operating temperature of the HP assembly and if applicable of the IP assembly. The temperature at which the heat is produced is determined by the temperature at which the gas G 1 is consumed in the reactor R′ 1 and if applicable the temperature at which the gas G 2 is consumed in the reactor R′ 2 . In step b) of regeneration, the heat is supplied to the reactor R′ 1 and if applicable to R′ 2 , at a temperature similar to that of the source of step a), and degraded heat is recovered in the reactor R′ 3 and if applicable in R′ 2 . The temperature at which the heat is introduced into R′ 1 and possibly into R′ 2 in the regeneration step may be lower than the temperature at which the heat is introduced into R′ 3 during the production step.
The heat Q produced at elevated temperature t in reactor R′ 1 (and possibly R′ 2 ) can be used for example in a heat exchanger or in a process requiring heat at said elevated temperature t. This use releases a certain quantity of heat Q′ at a lower temperature to such that Q′=Q[1−(t 0 /t)] corresponding to the exergy of the heat Q. This heat Q′ can advantageously be used in step b) to initiate the regeneration of the installation. In this particular embodiment of the method of the invention for producing heat, it is therefore unnecessary to dispose of a heat source external to the installation to regenerate the installation, and the heat can be produced at elevated temperature in R′ 1 (or R′ 1 and R′ 2 ) using one or a plurality of heat sources available elsewhere at lower temperature.
For the production of heat at a given temperature, the method of the invention is put into practice in an installation which comprises an HP assembly comprising the reactors R 1 and R′ 1 and an LP assembly comprising the reactors R 3 and R′ 3 , and it is characterized in that:
during a preliminary step:
the gas transfer means between R 1 and R′ 1 on the one hand, between R 3 and R′ 3 on the other are closed, the respective sorbents and gases are introduced into the reactors so that the reactor R 1 of the HP assembly contains the sorbent in a form rich in gas (B 1 ,G 1 ), the reactor R′ 1 is in a state to consume the gas G 1 , the reactor R 3 of the LP assembly contains the sorbent in a form poor in gas B 3 and the corresponding reactor R′ 3 is in a state to supply gas G 3 ,
during step a) of the production of heat, heat energy is added to R′ 3 to raise it to a temperature higher than the normal temperature, the gas transfer means are then opened between the reactors R 3 and R′ 3 on the one hand and the reactors R 1 and R′ 1 on the other, thereby causing the spontaneous liberation of gas G 3 in R′ 3 , the exothermic sorption of G 3 with the sorbent B 3 in R 3 , the endothermic desorption of the sorbent rich in gas (B 1 ,G 1 ) in R 1 , the exothermic consumption of the gas G 1 in R′ 1 with the production of heat; during step b), heat energy is added to R′ 1 to raise it to a temperature higher than the normal temperature, the gas transfer means are then opened between the reactors R 3 and R′ 3 on the one hand, and the reactors R 1 and R′ 1 , thereby causing the liberation of the gas G 1 in R′ 1 , the exothermic sorption of G 1 with the sorbent B 1 in R 1 , the endothermic desorption of the sorbent rich in gas (B 3 ,G 3 ) in R 3 , the exothermic consumption of the gas G 3 in R′ 3 , and the regeneration of the installation.
In view of the respective equilibrium curves of the reversible processes employed in the different reactors, the heat energy introduced during step a) in R′ 3 and during step b) in R′ 1 is at an intermediate temperature between the temperature at which heat is recovered in R′ 1 during step a), and the temperature at which the degraded heat is recovered in R′ 3 during step b).
In a specific embodiment, the method of the invention can be put into practice to produce a quantity of heat at a given place at a temperature higher than that of two heat sources located at another place. In this case, the method of the invention is put into practice in an installation which comprises three HP, LP and IP assemblies, respectively comprising the reactors R 1 ,R′ 1 , R 3 ,R′ 3 and R 2 ,R′ 2 , in the following conditions:
during a preliminary step,
the gas exchange means are closed between the reactors R 1 ,R′ 1 , R 3 ,R′ 3 and R 2 ,R′ 2 , the respective sorbents and gases selected are introduced into the reactors so that the reactor R 1 contains the sorbent in a form rich in gas (B 1 ,G 1 ), the reactor R′ 1 is in a state to consume the gas G 1 , the reactors R 3 and R 2 contain their respective sorbent in a form poor in gas B 3 and B 2 , and the reactors R′ 3 and R′ 2 are in a state to supply the respective gas G 3 and G 2 ;
during step a), heat energy is supplied to R′ 3 and R′ 2 to raise them to a temperature higher than the ambient temperature, the gas exchange means are then opened between the reactors R 3 ,R′ 3 , the reactors R 2 ,R′ 2 and the reactors R 1 ,R′ 1 , thereby causing the spontaneous liberation of G 3 in R′ 3 and of G 2 in R′ 2 , the exothermic sorption of G 3 with the sorbent B 3 in R 3 and the exothermic sorption of G 2 with the sorbent B 2 in R 2 , the endothermic desorption of the sorbent rich in gas (B 1 ,G 1 ) in R 1 , the exothermic consumption of G 1 in R′ 1 with the liberation of heat; during step b), heat energy is supplied to R′ 1 to raise it to a temperature higher than the normal temperature, the gas transfer means are then opened between the reactors R 3 ,R′ 3 , the reactors R 2 ,R′ 2 and the reactors R 1 ,R′ 1 , thereby causing the liberation of gas G 1 in R′ 1 , the exothermic sorption of G 1 with the sorbent B 1 in R 1 , the endothermic desorption of the sorbent rich in gas (B 3 , G 3 ) in R 3 and the sorbent rich in gas (B 2 ,G 2 ) in R 2 , and the exothermic consumption of the gas G 3 in R′ 3 and of the gas G 2 in R′ 2 .
In this embodiment, the heat introduced into the reactors R′ 2 and R′ 3 at an intermediate temperature is recovered in R′ 1 at a higher temperature during the production step, and the heat introduced into R′ 1 at an intermediate temperature is restored at a lower temperature during the regeneration step.
The method of the invention can furthermore produce heat in a phase during the production step, and regenerate the installation in two successive phases. The method is then put into practice in an installation which comprises three HP, LP and IP assemblies respectively comprising the reactors R 1 ,R′ 1 , R 3 ,R′ 3 and R 2 ,R′ 2 , in the following conditions:
during a preliminary step
the gas transfer means are closed between the different reactors, the respective sorbents and gases are introduced into the reactors, at normal temperature, so that R 1 and R 2 contain their respective sorbent in the state rich in gas (S 1 ,G 1 ) and (S 2 ,G 2 ), R 3 contains the sorbent in the state poor in gas, R′ 1 and R′ 2 are in a state to consume the gas G 1 and the gas G 2 respectively, and R′ 3 is in a state to liberate the gas G 3 ;
during step a), heat energy is introduced into R′ 3 , the gas transfer means are then opened between the reactors R 3 ,R′ 3 on the one hand and the reactors R 1 ,R′ 1 on the other, thereby causing the spontaneous liberation of G 3 in R 3 , the exothermic sorption of G 3 with the sorbent B 3 in R 3 , the endothermic desorption of the sorbent rich in gas (B 1 ,G 1 ) in R 1 , the exothermic consumption of the gas G 1 in R′ 1 with the production of heat at a higher temperature than that of the source supplying R′ 3 ; during step b), in a first phase, heat energy is introduced into R′ 1 , the gas transfer means are then opened between the reactors R 1 ,R′ 1 on the one hand and the reactors R 2 ,R′ 2 on the other, thereby causing the spontaneous liberation of G 1 , the exothermic sorption of G 1 with the sorbent B 1 in R 1 , the endothermic desorption of the sorbent rich in gas (B 2 ,G 2 ) in R 2 , and the exothermic consumption of the gas G 2 in R′ 2 ; in a second phase, heat energy is supplied to R′ 2 , the gas transfer means are then opened between the reactors R 2 ,R′ 2 on the one hand and the reactors R 3 ,R′ 3 on the other, thereby causing the liberation of gas G 2 , the exothermic sorption of G 2 with the sorbent B 2 in R 2 , the endothermic desorption of the sorbent rich in gas (B 3 ,G 3 ) in R 3 , and the exothermic consumption of the gas G 3 in R′ 3 .
The method of the invention furthermore serves to produce heat in two successive phases during the production step, and to regenerate the installation in one phase. The method is then put into practice in an installation that comprises three HP, LP and IP assemblies respectively comprising the reactors R 1 ,R′ 1 , R 3 ,R′ 3 and R 2 ,R′ 2 , in the following conditions:
during a preliminary step:
the gas transfer means are closed between the different reactors, the respective sorbents and gases are introduced into the reactors, at normal temperature, so that R 2 contains the sorbent in the state rich in gas (S 2 ,G 2 ), R 3 and R 1 contain their sorbent in the state poor in gas with B 3 and B 1 respectively, R′ 2 is in a state to consume the gas G 2 , and R′ 3 and R′ 1 are in a state to liberate the gas G 3 and G 2 respectively;
during step a) in a first phase, heat energy is introduced into R′ 3 , the reactors R 3 ,R′ 3 on the one hand and the reactors R 2 ,R′ 2 on the other are connected, thereby causing the spontaneous liberation of G 3 , the exothermic sorption of G 3 with the sorbent B 3 in R 3 , the endothermic desorption of the sorbent rich in gas (B 2 ,G 2 ) in R 2 , the exothermic consumption of G 2 in R′ 2 with the production of heat at a temperature higher than that of the source supplying R′ 3 ; in a second phase, heat energy is introduced into R′ 2 , the reactors R 1 ,R′ 1 on the one hand and the reactors R 2 ,R′ 2 on the other are connected, thereby causing the spontaneous liberation of G 2 , the exothermic sorption of G 2 with the sorbent B 2 in R 2 , the endothermic desorption of the sorbent rich in gas (B 1 ,G 1 ) in R 1 , the exothermic consumption of the gas G 1 in R′ 1 with the production of heat at a temperature higher than that of the source supplying R′ 2 ; during step b), heat energy is supplied to R′ 1 , the gas transfer means are then opened between the reactors R 1 ,R′ 1 on the one hand and the reactors R 3 ,R′ 3 on the other, thereby causing the liberation of gas G 1 , the exothermic sorption of G 1 with the sorbent B 1 in R 1 , the endothermic desorption of the sorbent rich in gas (B 3 ,G 3 ) in R 3 , and the exothermic consumption of the gas G in R′ 3 with the liberation of heat at a temperature lower than that of the energy source supplying R′ 1 .
In each specific case of the production of heat, during step a), a quantity of heat is brought to a higher temperature and is utilized, whereas during step b), a quantity of heat is brought to a lower temperature and consists of lost heat if the low temperature level is not useful.
The present invention is described in greater detail with the help of specific examples of operation and by reference to the corresponding Clapeyron diagrams. The description is based on reactors R′ i which are the seat of a liquid/gas phase change alternately operating as evaporator and as condenser for a gas G i . The transposition to installations wherein the reactors R′ i are the seat of a monovariant or divariant sorption is within the scope of the person skilled in the art. In the case of a divariant sorption, the equilibrium line in the corresponding reactor R′ i is a set of isosteres. In the diagrams, Ei and Ci respectively denote the evaporation and the condensation of the gas G i in the reactor R′ i .
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the Clapeyron diagram of an installation according to the invention comprising two assemblies operating with two solids and one gas for the production of cold.
FIG. 2 shows the Clapeyron diagram of an installation according to the invention comprising two assemblies operating with two solids and two gases for the production of cold.
FIG. 3 shows the Clapeyron diagram of an installation according to the invention comprising three assemblies operating with three solids and one gas for the production of cold.
FIG. 4 shows another Clapeyron diagram of an installation according to the invention comprising three assemblies operating with three solids and one gas for the production of cold.
FIG. 5 shows another Clapeyron diagram of an installation according to the invention comprising three assemblies operating with three solids and one gas for the production of cold.
FIG. 6 shows the Clapeyron diagram of an installation according to the invention comprising three assemblies operating with one solid and three gases for the production of cold.
FIG. 7 shows the Clapeyron diagram of an installation according to the invention comprising two assemblies operating with two solids and one gas for the production of heat.
FIG. 8 shows the Clapeyron diagram of an installation according to the invention comprising two assemblies operating with two solids and two gases for the production of heat.
FIG. 9 shows the Clapeyron diagram of an installation according to the invention comprising three assemblies operating with three solids and one gas for the production of heat.
FIG. 10 shows another Clapeyron diagram of an installation according to the invention comprising three assemblies operating with three solids and one gas for the production of heat.
FIG. 11 shows another Clapeyron diagram of an installation according to the invention comprising three assemblies operating with three solids and one gas for the production of heat.
FIG. 12 shows a specific case of a Clapeyron diagram of an installation according to the invention comprising two assemblies operating with one solid, one liquid and one gas for the production of cold.
FIG. 13 shows a specific case of a Clapeyron diagram of an installation according to the invention comprising two assemblies operating with two solids and one gas for the production of cold.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The production of cold in an installation comprising two HP and LP assemblies wherein the reactors R′ 1 and R′ 3 operate alternately as evaporator/condenser for the same gas G and the reactors R 1 and R 3 contain different sorbents B 1 and B 3 , is shown by the Clapeyron diagram shown in FIG. 1 . The sorptions in the reactors R 1 and R 3 are monovariant processes. G, B 1 and B 3 are selected so that, at the respective operating pressures, the sorption temperature S 1 is higher than the desorption temperature D 3 and the exothermic sorption temperature S 3 is higher than the desorption temperature D 1 .
In the initial state, the reactors R′ 1 and R′ 3 contain the gas G in liquid form, the reactor R 1 contains (B 1 ,G) and the reactor R 3 contains B 3 ; R 1 and R 3 are in thermal contact; the HP and LP assemblies are isolated from the atmospheric pressure and in a thermal relation with the ambient medium; during a first operating step, cold is produced at the temperature T 3B in the following manner: R 1 is communicated with R′ 1 , and R 3 with R′ 3 ; the HP assembly is placed at the pressure P 1B and the LP assembly at the pressure P 3B . The pressure and temperature (P,T) conditions in which the reactors R′ 3 , R 3 , R 1 and R′ 1 are then found are materialized respectively by E 3 , S 3 , D 1 and C 1 in the diagram. Owing to the very great affinity between B 3 and C, a spontaneous evaporation of G occurs in R′ 3 . The quantity of heat Q 3 required to evaporate the quantity of gas G necessary for the sorption S 3 is spontaneously withdrawn from the external medium, thereby producing cold at the temperature T 3B ; simultaneously, the quantity of heat Q′ 3 liberated in R 3 by the sorption S 3 is transmitted to the content of R 1 and causes the desorption D 1 by liberating the gas G. Said gas G is transported to the reactor R′ 1 operating as a condenser, where the release of a quantity of heat Q″ 3 at the temperature T 1B is observed; during a second step, the installation is regenerated: the gas exchange means between the reactors of the same assembly being closed, a quantity of heat Q 1 is introduced into the reactor R′ 1 to raise it to the temperature T 1H , the reactors R 1 ,R′ 1 on the one hand and the reactors R 3 and R′ 3 on the other are then placed in communication. In the HP assembly, the pressure settles at the equilibrium pressure P 1H , causing the evaporation of G in R′ 1 , the exothermic sorption S 1 in R 1 , the transfer of heat Q′ 1 released by the sorption S 1 to R 3 to cause the desorption D 3 , the liberation of the gas G in R 3 and its condensation in R′ 3 with the liberation of a quantity of heat Q″ 3 at the temperature T 3H . The conditions (P,T) in which the reactors R′ 3 , R 3 , R 1 and R′ 1 are then found are materialized respectively by the points C 3 , D 3 , S 1 and E 1 in the diagram. The installation is then again ready to produce cold. If the reactor R 3 and the reactor R′ 3 are isolated from each other at this time, the installation stores potential cold. The cold can be produced at any time by the simple communication of R 3 and R′ 3 at the pressure P 3B .
It therefore appears that cold can be produced at the temperature T 3B at the place where R′ 3 is located by supplying heat energy to a reactor R′ 1 which may be installed elsewhere, and particularly in a place where the heat energy is readily available. If the temperatures T 3H and T 1B are useful temperature levels, the installation serves simultaneously to produce cold in R′ 3 and heat in R′ 1 during the so-called cold production step, and degraded heat in R′ 3 during the regeneration step from the heat supplied to R′ 1 .
Cold is transported by the simple transport of the gas G in a pipe connecting the reactor R 1 and the reactor R′ 1 and in a pipe connecting the reactor R 3 and the reactor R′ 3 associated with it. The gas G and the sorbents B 1 and B 3 used are selected as a function of the temperature at which the cold is to be produced, and the temperature of the heat energy source available.
The theoretical cold production efficiency of such an installation, which can be written η P =Q 3 /Q 1 , is the ratio of the quantity of useful heat Q 3 to the quantity of heat introduced. In practice, it is close to 1.
The transport efficiency, which is defined by the ratio of the useful production in a remote site (Q P3 ) to the useful production made in situ (Q P1 ), can be written
η t =Q P3 /Q P1 +W= 1−(loss/ Q P1 +W )
where W is the gas pumping work. The transport of thermal energy with an installation according to the invention is not accompanied by heat losses, because the energy is transported in chemical form, by a simple gas circulation.
Another embodiment of the invention for the production of cold, and possibly of useful heat, is illustrated by FIG. 2 . The installation is similar to the one employed for the case shown in FIG. 1 , as well as the sequence of successive steps. The difference resides in the fact that the HP assembly operates with a working gas G 1 and the LP assembly operates with a working gas G 3 different from G 1 . In the initial state, the reactors R′ 1 and R′ 3 contain the respective gases G 1 and G 3 in liquid form, the reactor R 1 contains (B 1 ,G 1 ) and the reactor R 3 contains B 3 . As in the previous example, the pressure and temperature (P,T) conditions in which the reactors R′ 3 , R 3 , R 1 and R′ 1 are found are materialized respectively by E 3 , S 3 , D 1 and C 1 in the diagram. This means that, during the first operating step, the quantity Q 3 of cold produced in R′ 3 is at the temperature T 3B which is that of the evaporation of G 3 and the quantity of heat Q″ 3 produced in the reactor R′ 1 is at the temperature T 1B which is that of the condensation of G 1 . At the beginning of the second step, the conditions (P,T) in which the reactors R′ 3 , R 3 , R 1 and R′ 1 are found are materialized respectively by the points C 3 , D 3 , S 1 , and E 1 in the diagram. During this second step, the quantity of heat Q 1 required to evaporate the quantity of gas G 1 necessary for the sorption S 1 is introduced at the temperature T 1H which is that of evaporation of G 1 and the quantity of heat Q″ 1 liberated in R′ 3 is at the temperature T 3H which is that of the condensation of G 3 .
FIG. 3 shows the Clapeyron diagram corresponding to an installation according to the invention which comprises three HP, LP and IP assemblies. In this specific case, the gas G is identical in the three reactors R i , and the sorbents Bi are all different. Such an installation allows many variants in the production of cold. In particular it allows the production of cold at two different temperatures, successively or simultaneously in the reactors R′ 2 and R′ 3 , by the input of heat energy in R′ 1 during the regeneration of the installation. The gas G and the sorbents Bi are selected so that, at the respective operating pressures, the temperatures of the sorptions S 2 and S 3 are substantially identical to each other and slightly higher than the temperature of the desorption D 1 , and so that the temperature of the sorption S 1 is slightly higher than the temperatures of the desorptions D 2 and D 3 , said desorption temperatures being substantially identical. In the initial state, the three reactors R′ i contain the gas G in liquid form, the reactor R 1 contains the sorbent in a form rich in gas (B 1 ,G) and the reactors R 2 and R 3 contain the sorbent in a form poor in gas, respectively B 2 and B 3 ; the reactors R i and R′ i of an assembly are not in communication with each other; the reactors R i are in thermal communication; the assemblies are isolated from the atmospheric pressure and are in thermal relation with the ambient medium.
During a first operating step, cold is produced at the temperatures T 2B and T 3B in the following manner: R 1 is communicated with R′ 1 , R 2 with R′ 2 and R 3 with R′ 3 ; in view of the very great affinity between B 2 and G on the one hand, and B 3 and G on the other, a spontaneous evaporation of G occurs in R′ 2 and in R′ 3 (materialized respectively by E 2 and E 3 in the figure). The quantity of heat required to evaporate the quantity of gas G necessary for the sorption S 2 and the quantity of heat required to evaporate the quantity of gas G necessary for the sorption S 3 are withdrawn spontaneously from the external medium, thereby producing cold at the temperatures T 2B and T 3B ; simultaneously, the quantities of heat liberated respectively in R 2 and in R 3 by the sorption are transmitted to the content (B 1 ,G) of R 1 and cause the desorption D 2 by liberating the gas G. Said gas G is transported to the reactor R′ 1 operating as a condenser (denoted C 1 in the figure), where a release of heat at the temperature T iB is observed; during a second step, the installation is regenerated, each of the assemblies of reactors in the installation is at its high pressure level P iH : a quantity of heat is introduced into R′ 1 which operates as an evaporator (denoted E 1 in the figure), said quantity required to raise it to the temperature T 1H , the two reactors of each assembly are then communicated, thereby causing the evaporation of gas G in R′ 1 , and the sorption S 1 in R 1 ; the quantity of heat released by the sorption is transmitted to the content of the reactors R 2 and R 3 and causes the desorptions D 2 and D 3 ; the gas liberated is transmitted to the reactors R′ 2 and R′ 3 in which it is condensed by liberating heat (denoted respectively C 2 and C 3 in the figure) respectively at the temperatures T 3H and T 2H ; at the end of this step, the installation is again ready to supply cold. If each of the reactors R 2 and R 3 is isolated from the respective reactor R′ 2 and R′ 3 at this time, the installation stores potential cold, which can be liberated at any time by the simple communication of R 2 and R′ 2 on the one hand and of R 3 and R′ 3 on the other.
To produce cold selectively at the temperature T 2B or at the temperature T 3B , the first step is carried out by connecting the reactors R 1 and R′ 1 on the one hand and, on the other, either the reactors R 3 and R′ 3 in order to produce cold at T 3B , or the reactors R 2 and R′ 2 .
FIG. 4 shows the Clapeyron diagram corresponding to an installation according to the invention which comprises three assemblies of two reactors. As in the previous case, the working gas G is identical in the three reactors R i , and the sorbents Bi are all different. At the start of the process, the reactor R 3 contains B 3 and the other two reactors respectively contain (B 1 ,G) and (B 2 ,G), and the whole system is at ambient temperature.
During a first step, R 3 is connected with R′ 3 and R 2 is connected with R′ 2 , thereby initiating the evaporation of G with the production of cold at the temperature T 3B , the sorption S 3 in R 3 with the production of heat transmitted to (B 2 ,G) contained in R 2 , which causes the desorption D 2 and the liberation of gas G which condenses in R′ 2 with the liberation of heat at the temperature T 2H . The conditions (P,T) in which the reactors R′ 3 , R 3 , R 2 and R′ 2 are found during this step are materialized respectively by the points E 3 , S 3 , D 2 and C 2 in the diagram; during a second step, the production of cold is caused similarly at R′ 2 by the contacting of R 2 and R′ 2 on the one hand and of R 1 and R′ 1 on the other, thereby causing the sorption S 2 which supplies to R 1 the heat necessary for the desorption D 1 followed by the production of heat at the temperature T 1B due to the condensation in R′ 1 of the liberated gas. The conditions (P,T) in which the reactors R′ 2 , R 2 , R 1 and R′ 1 are found in this step are materialized respectively by the points E 2 , S 2 , D 1 and C 1 in the diagram; during a third step, the system is regenerated by supplying heat to R′ 1 to raise it to the temperature T 1H , and R 3 and R′ 3 on the one hand and R 1 and R′ 1 on the other are then contacted, to liberate the gas G in the direction of R 1 for the sorption S 1 . The heat liberated is transferred in R 3 for the desorption D 3 and the production of heat in R′ 3 by condensation of the liberated gas. The conditions (P,T) in which the reactors R′ 3 , R 3 , R 1 and R′ 1 are found during this step are materialized respectively by the points C 3 , D 3 , S 1 and E 1 in the diagram. The installation is then ready for a new cold production sequence.
The respective cold production temperatures T 2B and T 3B are substantially the same. It is therefore possible to produce a large quantity of cold, since it corresponds to two evaporation processes.
FIG. 5 shows the Clapeyron diagram corresponding to an installation according to the invention which comprises three assemblies of two reactors. As in the previous case, the working gas G is identical in the three reactors R i , and the sorbents Bi are all different. At the start of the process, the reactor R 3 contains B 3 and the other two reactors contain (B 1 ,G) and (B 2 ,G) respectively, at ambient temperature. A difference from the previous examples resides in the fact that, during the cold production step, only the reactor R 3 operates in sorption mode with the production of cold in the reactor R′ 3 at the temperature T 3B .
During a first step, the connection of R 3 and R′ 3 and of R 1 and R′ 1 causes the spontaneous evaporation of the gas G in R′ 3 . The liberated gas G causes the sorption S 3 with release of heat which is transferred to R 1 to cause there the desorption D 1 , the condensation of the gas liberated in R′ 1 with the production of heat at the temperature T 1B ; during a second step, heat is added to the reactor R′ 1 to raise it to the temperature T 1H , R 1 and R′ 1 are then contacted on the one hand, R 2 and R′ 2 on the other, with the effect of liberating the gas G necessary for the sorption S 1 in R 1 , the heat released being transferred to R 2 for the desorption D 2 and the liberation of G which condenses in R′ 2 with the production of heat; during a third step, heat is added to R′ 2 to raise it to the temperature T 2H , R 3 and R′ 3 are then contacted on the one hand, R 2 and R′ 2 on the other, with the effect of liberating the gas G necessary for the sorption S 2 in R 2 , the heat released being transmitted to R 3 for the desorption of (B 3 ,G) formed during the previous step, so that the installation is regenerated for a new cold production sequence at T 3B .
This embodiment serves to produce cold at a very low temperature.
FIG. 6 shows the Clapeyron diagram corresponding to an installation similar to the one shown in FIG. 3 and operating in the same manner. The only difference resides in the fact that a different working gas is used in each assembly. The cold is produced during a first step in the reactors R′ 2 and R′ 3 at the temperatures T 2B and T 3B and the installation is regenerated during a second step by adding heat energy to R′ 1 operating as an evaporator at the elevated temperature T 1H .
FIG. 7 shows the Clapeyron diagram corresponding to an installation according to the invention which is similar to the one used in the embodiment in FIG. 1 and which comprises two reactors R 1 and R 3 and two associated reactors R′ 1 and R′ 3 , but operating to produce a quantity of heat at a temperature higher than that of the source. In the initial state, the reactors R′ 1 and R′ 3 contain the gas G in liquid form, the reactor R 1 contains (B 1 ,G) and the reactor R 3 contains B 3 ;
during a first operating step, heat is produced at the temperature T 1H in the following manner: heat energy is added to R′ 3 to raise it to the temperature T 3H , R 1 is then communicated with R′ 1 , and R 3 with R′ 3 , causing the spontaneous evaporation of G in R′ 3 with the production of cold, the transfer of G in R 3 for the sorption S 3 , the transfer of the heat liberated by the sorption to R 1 and the desorption in R 1 , the transfer of the gas liberated to R′ 1 and condensation with the liberation of heat at the temperature T iH ; during a second step, the installation is regenerated, by adding heat to R′ 1 to raise it to the temperature T 1B , then by communicating the reactors of the same assembly, thereby causing the evaporation of G in R′ 1 , the transfer of G to R 1 , the exothermic sorption in R 1 , the transfer of the heat released to R 3 , the desorption in R 3 , the transfer and the condensation of the gas to R′ 3 with the release of heat at a temperature lower than the ambient temperature; the installation is then ready for a new heat production step at a temperature level higher than that of the source.
In this embodiment, heat can be produced at a given place using a heat source located at another place, the heat being produced at a temperature level higher than that of the source, by simply transporting a gas in a pipe connecting the reactor R 1 and the reactor R′ 1 (evaporator/condenser in the present case) on the one hand, and the reactor R 3 and the evaporator/condenser R′ 3 associated with it on the other. The working gas G and the sorbents B 1 and B 3 used are selected as a function of the temperature at which the heat is to be produced, and of the temperature of the heat energy source available.
Another embodiment of the invention for the production of heat is shown in FIG. 8 . The installation is similar to the one employed for the case shown in FIG. 7 , as well as the sequence of successive steps. The difference resides in the fact that the gases G 1 and G 3 are different. In the initial state, the reactors R′ 1 and R′ 3 contain the respective gases G 1 and G 3 in liquid form, the reactor R 1 contains (B 1 ,G 1 ) and the reactor R 3 contains B 3 . This means that, during the first operating step, the quantity of useful heat is produced in R′ 1 at the temperature T 1H which is that of the condensation of G 1 and during the second regeneration step, the quantity of degraded heat recovered in R′ 3 is at the temperature T 3B which is that of the condensation of G 3 .
FIG. 9 shows the Clapeyron diagram corresponding to the production of heat in an installation similar to the one used for the production of cold in the example shown in FIG. 3 .
At the beginning of the process, the reactors R 2 and R 3 contain B 2 and B 3 respectively, the reactor R 1 contains (B 1 ,G), and the corresponding reactors R′ i contain the gas G in its liquid form.
In a first step, sufficient quantities of heat are introduced respectively in R′ 2 and R′ 3 , said quantities being necessary to raise them to the respective temperatures T 2H and T 3H which are higher than the ambient temperature, and the reactors of each assembly are then communicated. The gas G evaporates spontaneously in R′ 2 and R′ 3 , causing the sorptions S 2 and S 3 . The heat released during each sorption is transmitted to the reactor R 1 for the desorption D 1 which liberates gas G which condenses in R′ 1 , producing useful heat at the temperature T 1H ; in a second step, heat is introduced into R′ 1 to raise it to the temperature T 1B , and the reactors of each assembly are then communicated. The gas G evaporates spontaneously in R′ 1 causing the sorption S 1 ; the heat released by S 1 is transmitted to R 2 and R 3 , causing the desorptions D 2 and D 3 , so that the installation is again in a state to produce heat. If the reactors R′ 2 and R 2 on the one hand, and R′ 3 and R 3 on the other, are not connected, the heat is stored. Since storage takes place in chemical form, there are no heat losses.
FIG. 10 shows the Clapeyron diagram corresponding to an installation according to the invention which comprises three HP, LP and IP assemblies. The working gas G is identical in the three reactors R i , and the sorbents Bi are all different. The production of useful heat takes place in R′ 1 operating as a condenser at its highest pressure level, thereby corresponding to the highest temperature of the installation. The installation is regenerated in two steps by the introduction of heat at an intermediate temperature level.
At the start of the process, the reactor R 3 contains B 3 and the other two reactors contain (B 1 ,G) and (B 2 ,G) respectively, at ambient temperature.
During a first step, heat is introduced into R′ 3 to raise it to the temperature T 3H higher than the ambient temperature, R 3 and R′ 3 are then communicated on the one hand, and R 1 and R′ 1 on the other; the spontaneous evaporation of G in R′ 3 causes the sorption S 3 in R 3 with the production of heat transmitted to (B 1 ,G) contained in R 1 , then the desorption D 1 and the liberation of gas G which condenses in R′ 1 with the liberation of heat at the temperature T 1H higher than T 3H ; during a second step, heat is introduced into R′ 1 to raise it to a temperature T 1B higher than the ambient temperature, R 2 and R′ 2 are then communicated on the one hand, and R 1 and R′ 1 on the other; the spontaneous liberation of G in R′ 1 causes the sorption S 1 which supplies to R 2 the heat necessary for the desorption D 2 , and the condensation of G in R′ 2 ; during a third step, heat is supplied to R′ 2 , R 2 and R′ 2 are then communicated on the one hand, and R′ 3 and R 3 on the other, to liberate the gas G in the direction of R 2 for the sorption S 2 . The heat liberated is transferred in R 3 for the desorption D 3 . The installation is then ready for a new heat production sequence.
In this embodiment, the installation according to the invention produces heat utilized at a high level during the first step, and regeneration takes place during the 2 nd and 3 rd steps.
FIG. 11 shows the Clapeyron diagram corresponding to an installation according to the invention which comprises three HP, LP and IP assemblies. The working gas G is identical in the three reactors R i , and the sorbents Bi are all different.
At the start of the process, the reactor R 3 contains B 3 and the other two reactors contain (B 1 ,G) and (B 2 ,G) respectively.
During a first step, heat is introduced into R′ 3 , the heat necessary to raise it to the temperature T 3H , R 3 and R′ 3 are then communicated on the one hand, and R 2 and R′ 2 on the other; the evaporation of G in R′ 3 causes the sorption S 3 in R 3 with the production of heat transmitted to (B 2 ,G) contained in R 2 , then the desorption D 2 and the liberation of gas G which condenses in R′ 2 with the liberation of heat at the temperature T 2H ; during a second step, R′ 2 is raised to the temperature T 2H , R 2 and R′ 2 are then communicated on the one hand, and R 1 and R′ 1 on the other, causing the sorption S 2 which supplies to R 1 the heat necessary for the desorption D 1 ; the liberated gas condenses in R 1 while liberating heat at the temperature T 1H ; during a third step, heat is supplied to R′ 1 to raise it to the temperature T 1B , R 1 and R′ 1 are then communicated on the one hand, and R′ 3 and R 3 on the other to liberate the gas G in the direction of R 1 for the sorption S 1 . The heat liberated is transferred in R 1 for the desorption D 3 . The installation is then ready for a new heat production sequence.
In this embodiment of the installation with three assemblies according to the invention, the heat is produced at an elevated temperature level during the first two steps of the operating cycle, and the installation is regenerated during the third step.
FIG. 12 shows the theoretical Clapeyron diagram of a specific installation comprising two assemblies operating for the production of cold. In the two assemblies, the working gas is ammonia and the reactors R′ 1 and R′ 3 consequently operate alternatively as a condenser and an evaporator of NH 3 . In the HP assembly, the reactor R 1 is the seat of a reaction of NH 3 with CaCl 2 . In the LP assembly, the reactor is the seat of a reversible absorption of NH 3 by water according to the equation
NH 3 +H 2 O.x 1 NH 3 ⇄H 2 O.x 2 NH 3
where x 1 =0.1 and x 2 =0.2. Since the process is bi-variant, the equilibrium line shifts as a function of the quantity of NH 3 absorbed. During the startup of such an installation, CaCl 2 is in a gas rich form and the water is poor in gas. The connecting of the reactors R′ 3 and R 3 places them at a pressure of about 4 bar, causing the evaporation of NH 3 at 0° C. and the absorption of NH 3 by the water at an initial temperature of 90° C. As the water is enriched with ammonia, the temperature decreases in R 3 to the value of 80° C. when the ammonia content x in the water reaches 0.2. At the same time, the heat liberated by the absorption of ammonia in the water is transmitted to the reactor R 1 to decompose the calcium chloride rich in ammonia. The liberated ammonia condenses in R′ 1 at 40° C. while liberating heat. To regenerate the installation, heat is introduced in R′ 1 to evaporate the ammonia which is adsorbed on CaCl 2 at a temperature of 163° C. The heat liberated is transmitted to the reactor R 3 to liberate part of the ammonia absorbed in the water, said liberation beginning when the temperature in R 3 is 140° C., corresponding to the equilibrium temperature for an ammonia concentration of 0.2 in the water. If the heat produced at 40° C. is useful, the installation operates for the simultaneous production of cold and heat.
FIG. 13 shows the experimental Clapeyron diagram of an installation with two assemblies operating for the production of cold. In the two assemblies, the working gas is ammonia and the reactors R′ 1 and R′ 3 consequently operate alternatively as condenser and evaporator of NH 3 . In the HP assembly, the reactor R 1 is the seat of a reaction of NH 3 with MgCl 2 according to the equation MgCl 2 .2NH 3 +NH 3 ⇄MgCl 2 .6NH 3 . In the LP assembly, the reactor is the seat of a reaction of NH 3 with NiCl 2 according to the equation NiCl 2 .2NH 3 +NH 3 ⇄NiCl 2 .6NH 3 . During the cold production step, the ammonia is evaporated in R′ 3 while producing cold at −5° C., the exothermic reaction in the nickel chloride occurs at 220° C. and the heat is transferred in R 1 for the desorption of the magnesium chloride rich in ammonia, at 220° C., the liberated ammonia condensing in R′ 1 at 30° C. while liberating heat. During the regeneration step, heat is introduced into R′ 1 at 78° C. to evaporate NH 3 which is fixed on the Mg chloride while liberating heat which is transferred in R 3 at 265° C. to decompose the nickel chloride rich in ammonia and the installation is again ready to produce cold. The reactor R′ 3 is installed at the place where the cold is used, the reactor R′ 1 is installed at the place where the heat energy is available. The cold energy is thus transported by a chemical method avoiding any heat losses. | A method and installation is described for producing cold and/or heat, in a place where the latter are to be used, from one or more heat energy sources. The method is carried out in an installation comprising two or three assemblies of two reactors in which reversible phenomena involving a gas take place, said phenomena being exothermic in the sense of synthesis and endothermic in the sense of decomposition. The energy for the operation of the installation is supplied by a low temperature reactor of one or two assemblies. The installation is suitable for the remote production of cold or heat by means of the transport of gas at ambient temperature. | 70,157 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of U.S. patent application Ser. No. 13/658,735, filed Oct. 23, 2012, entitled, “VIRTUAL MULTICARRIER DESIGN FOR ORTHOGONAL FREQUENCY DIVISION MULTIPLE ACCESS COMMUNICATIONS,” which is a continuation of U.S. patent application Ser. No. 12/242,755 filed Sep. 30, 2008, entitled, “VIRTUAL MULTICARRIER DESIGN FOR ORTHOGONAL FREQUENCY DIVISION MULTIPLE ACCESS COMMUNICATIONS,” the entire specification of which is hereby incorporated by reference in its entirety for all purposes.
FIELD
Embodiments of the present disclosure relate to the field of wireless access networks, and more particularly, to virtual multicarrier design for orthogonal frequency division multiple access communications in said wireless access networks.
BACKGROUND
Orthogonal frequency division multiple access (OFDMA) communications use an orthogonal frequency-division multiplexing (OFDM) digital modulation scheme to deliver information across broadband networks. OFDMA is particularly suitable for delivering information across wireless networks.
The OFDM digital modulation scheme uses a large number of closely-spaced orthogonal subcarriers to carry information. Each subcarrier is capable of carrying a data stream across a network between OFDMA terminals.
OFDMA-based communication systems are well known to have out of band emission (OOBE) issues that result in intercarrier interference (ICI). Prior art networks control this ICI by providing guard bands, e.g., unused subcarriers, between adjacent carriers.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments will be readily understood by the following detailed description in conjunction with the accompanying drawings. To facilitate this description, like reference numerals designate like structural elements. Embodiments are illustrated by way of example and not by way of limitation in the figures of the accompanying drawings.
FIG. 1 illustrates a wireless communication environment in accordance with embodiments of this disclosure.
FIG. 2 is a flowchart depicting operations of a base station in accordance with some embodiments.
FIG. 3 is a flowchart depicting operations of a mobile station in accordance with some embodiments.
FIG. 4 is a graph illustrating OOBE on two adjacent carriers in accordance with some embodiments.
FIG. 5 illustrates various views of a configuration of assigned bandwidth in accordance with some embodiments.
FIG. 6 illustrates an OFDMA frame in accordance with some embodiments.
FIG. 7 illustrates a multicarrier transmission being processed with and without reuse of guard band subcarriers in accordance with some embodiments.
FIG. 8 illustrates how teachings of various embodiments facilitate a flexible deployment and upgrading of network equipment in accordance with some embodiments.
FIG. 9 illustrates a computing device capable of implementing a virtual carrier terminal in accordance with some embodiments.
DETAILED DESCRIPTION
In the following detailed description, reference is made to the accompanying drawings which form a part hereof wherein like numerals designate like parts throughout, and in which is shown by way of illustration embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of embodiments in accordance with the present invention is defined by the appended claims and their equivalents.
Various operations may be described as multiple discrete operations in turn, in a manner that may be helpful in understanding embodiments of the present invention; however, the order of description should not be construed to imply that these operations are order dependent.
For the purposes of the present invention, the phrase “A and/or B” means “(A), (B), or (A and B).” For the purposes of the present invention, the phrase “A, B, and/or C” means “(A), (B), (C), (A and B), (A and C), (B and C), or (A, B and C).”
The description may use the phrases “in an embodiment,” or “in embodiments,” which may each refer to one or more of the same or different embodiments. Furthermore, the terms “comprising,” “including,” “having,” and the like, as used with respect to embodiments of the present invention, are synonymous.
Embodiments of the present disclosure describe virtual multicarrier designs for OFDMA communications as may be used by multicarrier transmission schemes presented in, e.g., the Institute of Electrical and Electronics Engineers (IEEE) 802.16—2004 standard along with any amendments, updates, and/or revisions (e.g., 802.16m, which is presently at predraft stage), 3 rd Generation Partnership Project (3GPP) long-term evolution (LTE) project, ultra mobile broadband (UMB) project (also referred to as “3GPP2”), etc.
FIG. 1 illustrates a wireless communication environment 100 in accordance with an embodiment of this disclosure. In this embodiment, the wireless communication environment 100 is shown with three wireless communication terminals, e.g., base station 104 , mobile station 108 , and mobile station 112 , communicatively coupled to one another via an over-the-air (OTA) interface 116 .
In various embodiments, the mobile stations 108 and 112 may be a mobile computer, a personal digital assistant, a mobile phone, etc. The base station 104 may be a fixed device or a mobile device that may provide the mobile stations 108 and 112 with network access. The base station 104 may be an access point, a base transceiver station, a radio base station, a node B, etc.
The wireless communication devices 104 , 108 , and 112 may have respective antenna structures 120 , 124 , and 128 to facilitate the communicative coupling. Each of the antenna structures 120 , 124 , and 128 may have one or more antennas. An antenna may be a directional or an omnidirectional antenna, including, e.g., a dipole antenna, a monopole antenna, a patch antenna, a loop antenna, a microstrip antenna or any other type of antenna suitable for transmission/reception of radio frequency (RF) signals.
Briefly, the base station 104 may have a baseband processing block (BPB) 132 coupled to a transmitter 136 . The BPB 132 may be configured to encode input data, which may be received in a binary format, as an OFDM signal on logical subcarriers of a virtual carrier. The logical subcarriers may be mapped to physical subcarriers from at least two adjacent physical carriers. The BPB 132 may then control the transmitter 136 to transmit the OFDM signal on the physical subcarriers.
FIG. 2 is a flowchart depicting operations of the base station 104 in accordance with some embodiments. At block 204 , an encoder 140 of the BPB 132 may receive input data from upper layers of the base station 104 .
At block 208 , the encoder 140 may encode the input data into frequency domain OFDM signal having logical subcarriers of a virtual carrier.
At block 212 , the encoder 140 may map the logical subcarriers to physical subcarriers of one or more physical carriers according to a mapping scheme provided by the mapper 144 .
In some embodiments, the mapping scheme may map indices of the logical subcarriers to indices of the physical subcarriers. For example, consider a simple embodiment in which the encoder 140 encodes an OFDMA signal onto 20 logical subcarriers of a virtual carrier. The logical subcarriers may have indices 1-20. A mapping scheme may map the logical subcarrier indices 1-20 to physical subcarrier indices 1-5 of a first physical carrier, physical subcarrier indices 1-5 of a second physical carrier, and physical subcarrier indices 1-10 of a third physical carrier. In an actual implementation, the number of subcarriers will be significantly higher. Furthermore, the total number of logical subcarriers need not be equal to the total number of physical subcarriers as is described in this example.
The frequency domain OFDM signal may be provided to an inverse fast Fourier transformer (IFFT) 148 that transforms the signal into a time domain OFDM signal, having a plurality of time domain samples for associated physical subcarriers.
At block 216 , the transmitter 136 may be controlled to transmit the physical subcarriers. The transmitter 136 may provide a variety of physical layer processing techniques, e.g., adding cyclic prefix, upconverting, parallel-to-serial conversion, digital-to-analog conversion, etc. to effectuate the transmission.
The receiving process of the mobile stations may operate in a manner that complements the transmitting process described above.
FIG. 3 is a flowchart depicting operations of the mobile station 108 in accordance with some embodiments. At block 304 , a receiver 152 of the mobile station 108 may receive the physical carriers that carry the OFDM signal via the OTA interface 116 , process the OFDM signal and present it, as a time domain OFDM signal, to a BPB 156 . The complementary physical layer processing techniques of the receiver 152 may include, e.g., removing cyclic prefix, down converting, serial-to-parallel conversion, analog-to-digital conversion, etc. to effectuate reception and facilitate subsequent processing.
The BPB 156 may include a fast Fourier transformer (FFT) 160 to receive the time domain OFDM signal from the receiver 152 . The FFT 160 may generate a frequency domain OFDM signal and forward the signal to a decoder 164 .
At block 308 , the decoder 164 may map the physical subcarriers of the physical carriers to logical subcarriers of the virtual carrier according to the mapping scheme provided by mapper 168 . In some embodiments, information related to the mapping scheme may be transmitted to the mobile station 108 from the base station 104 in, e.g., downlink (DL) control messages, DL broadcast channel messages, etc.
At block 312 , the decoder 164 may decode the logical subcarriers to retrieve the transmitted data. This data may then be output to upper layers of the mobile station 108 at block 316 .
The use of virtual multicarriers for communications between terminals may, for example, allow a base station to scale its bandwidth, provide support for mobile stations having various bandwidths, facilitate deployment and upgrading of network equipment due, at least in part, to legacy support, etc. These aspects will be discussed in further detail below.
While the described embodiments discuss the base station 104 transmitting, and the mobile station 108 receiving, on virtual carriers, other embodiments may additionally/alternatively include the mobile station 108 transmitting, and the base station 104 receiving, on virtual channels.
Furthermore, various embodiments of this disclosure describe aligning subcarriers of adjacent physical carriers of a virtual carrier. As used herein, subcarrier of adjacent physical carriers may be aligned if the spacing between a subcarrier of a first physical carrier and a subcarrier of a second physical carrier is equal to, or a multiple of, a spacing between adjacent subcarriers within the first (or second) physical carrier. This alignment may reduce, either in part or in total, ISI, which may, in turn, enable use of subcarriers traditional reserved for guard band. Using these subcarriers for data transmission may increase an overall spectrum utilization ratio.
To understand the effect of subcarrier spacing between adjacent carriers, consider an OFDM signal that is expressed in the time domain as:
y
(
t
)
=
∑
k
=
0
M
-
1
X
(
k
)
ⅇ
j
2
π
q
k
Δ
ft
,
0
≤
t
≤
T
u
,
T
u
Δ
f
=
1
,
q
k
:
int
∈
[
-
N
2
,
N
2
-
1
]
Eq
.
1
and in the frequency domain as:
y
(
t
)
=
T
u
∑
k
=
0
M
-
1
X
(
k
)
Sinc
(
(
f
-
q
k
Δ
f
)
T
u
)
ⅇ
-
j
2
π
(
g
-
q
k
Δ
f
)
T
u
Eq
.
2
where M is the number of used subcarriers, T u is useful symbol duration, q k is the position, or index, of the used subcarrier. Eq. 2 may be used to calculate the average power spectrum as:
E
{
Y
(
f
)
2
}
=
σ
s
2
∑
k
=
0
M
-
1
Sinc
(
(
f
-
q
k
Δ
f
)
T
u
2
=
σ
s
2
sin
(
β
π
)
2
∑
k
=
0
M
-
1
1
π
(
f
-
q
k
Δ
f
)
T
u
2
,
Eq
.
4
Eq
.
3
where β is a misalignment factor that ranges from 0˜1, and σ s is an expression of subcarrier energy.
FIG. 4 is a graph illustrating OOBE on two adjacent carriers 404 and 408 that have a maximum misalignment factor of 0.5, a 10 MHz bandwidth, 840 subcarriers, and no low-pass filter. As can be seen, there is a 0 to −29 dB interference signal at guard band subcarriers.
The power of the interference signal from a neighboring carrier may be:
10
log
(
σ
s
2
∑
k
=
0
M
-
1
1
π
(
f
-
q
k
Δ
f
)
T
u
2
)
+
10
log
(
sin
(
β
π
2
)
.
Eq
.
5
When the subcarriers of adjacent carriers are aligned, as described in accordance with various embodiments, the alignment factor β=0 and the value of the expression “10 log(|sin(βπ| 2 )” of Eq. 5 will go to negative infinity. Accordingly, there will be no (or very little) interference due to OOBE after the neighboring carriers are well aligned.
The alignment of the subcarriers in adjacent carriers may be accomplished in a variety of ways. In one embodiment, the IFFT 148 may be one transformer that utilizes all of the frequency domain samples corresponding to one virtual channel as one vector input group. In this manner, the subcarriers across an entire virtual carrier of, e.g., a 20 MHz band, may then be equally spaced. The 20 MHz band may be subdivided into various physical carriers, e.g., two 5 MHz and one 10 MHz carriers.
In another embodiment, the IFFT 148 may include more than one transformer, e.g., it may include a transformer for each physical carrier, with each transformer producing a physical carrier. In this embodiment, each of the distinct transformers may perform transform functions on distinct vector input groups of the frequency domain samples. When separate transformers are used to independently produce physical carriers, care may be taken to ensure that subcarriers of adjacent carriers are aligned. In various embodiments, subcarrier alignment may be performed by changing the channel raster to, e.g., 175 kHz; by shifting the center frequency of adjacent carriers; and/or to change the subcarrier spacing to, e.g., 12.5 kHz.
FIG. 5 illustrates various views of a configuration of assigned bandwidth 500 in accordance with embodiments of this disclosure. In this embodiment, the assigned bandwidth 500 may be a 20 MHz band. The base station 104 may configure the assigned bandwidth 500 as three physical carriers, e.g., physical carrier (PC) 504 , PC 508 , and PC 512 . PCs 504 and 508 may be 5 MHz bands, while the PC 512 may be a 10 MHz band. A “physical carrier,” as used herein, may refer to a continuous spectrum of radio frequencies in which at least one mobile station of the wireless communication environment 100 is capable of, and restricted to, communicating with the base station.
The configured PCs may be viewed differently according to the capabilities of the receiving terminal. A terminal capable of communicating with virtual carriers (hereinafter also referred to as “VC terminal”) may have a VC terminal view 516 , while a terminal not able to communicate with virtual carriers (hereinafter also referred to as “legacy terminal”) may have a legacy terminal view 520 . The base station 104 may adapt communications accordingly.
The base station 104 may communicate with a VC terminal having a 20 MHz receiver by a virtual carrier shown in the VC terminal view 516 . With the subcarriers of adjacent PCs being aligned, e.g., PC 504 and 508 and/or PC 508 and PC 512 , the base station 104 may utilize at least some of the edge subcarrier groups, which are reserved as guard band subcarriers in prior art systems, for communication. As used herein, “an edge subcarrier group” may be a group of consecutive subcarriers of a particular PC that includes a subcarrier that is adjacent to subcarriers of an adjacent PC.
Edge subcarrier groups that are adjacent to a PC of a common virtual carrier may be referred to as interior edge subcarrier groups. In FIG. 5 , the interior edge subcarrier groups may be groups 524 , 528 , 532 , and 536 . Given the subcarrier alignment, these interior edge subcarrier groups may be utilized for communications. However, in order to avoid ICI with PCs external to the virtual carrier, the groups 540 and 544 , or external edge subcarrier groups, may be reserved for a guard band.
The base station 104 may communicate with legacy terminal by PC 504 , 508 , or 512 as seen in the legacy terminal view 520 . Each legacy terminal will only be capable of receiving data communications on one of the PCs. Furthermore, unlike the VC terminals, a legacy terminal will see the edge subcarrier groups 524 , 528 , 532 , and 536 as being reserved for a guard band. Accordingly, the legacy terminal will not be able to transmit or receive on subcarriers within these groups.
Communications between the base station 104 and a legacy terminal will not compromise a contemporaneous communication of the base station 104 and a VC terminal that uses the full range of available subcarriers.
FIG. 6 illustrates an OFDM frame 600 in accordance with embodiments of the present disclosure. In this embodiment, PCs 604 , 608 , and 612 are shown. PCs 604 and 608 may each have, e.g., a 10 MHz band, while PC 612 may have a 5 MHz band. Each PC may include a preamble 616 , edge subcarriers 620 , and a broadcast messaging section 624 .
In one embodiment, the base station 104 may encode data onto a first virtual carrier (VC1) that includes all three of the PCs 604 , 608 , and 612 . In this embodiment, one or more receiving terminals including, e.g., mobile station 108 , may have a 25 MHz receiver that accommodates the entire range of VC1.
The base station 104 may transmit allocation information on a common messaging section 628 to communicate DL and UL allocations to VC terminals. In this embodiment, the base station 104 may use the common messaging section 628 to inform the mobile station 108 that downlink communications will be sent to the mobile station 108 at resource 632 and that the mobile station 108 may upload information to the base station 104 at resource 636 . As can be seen, the resource 632 may incorporate edge subcarriers of PCs 604 and 608 .
The base station 104 may also encode data onto other virtual carriers that include various subsets of adjacent PCs. For example, the base station 104 may encode data onto a second virtual carrier (VC2) that includes only PC 604 and PC 608 . VC2 may be used for communications with VC terminals having 20 MHz receivers. Hereinafter, a VC terminal having a 20 MHz receiver may also be referred to as a 20 MHz VC terminal. In this embodiment, the base station 104 may communicate, to a particular 20 MHz VC terminal, DL allocations at resource 640 and UL allocations at resource 644 , which also includes edge subcarrier groups of PC 604 and PC 608 .
The base station 104 may additionally/alternatively encode data onto a third virtual carrier (VC1) that includes only PC 608 and PC 612 . VC3 may be used for communications with 15 MHz VC terminals. In this embodiment, the base station 104 may communicate, to a particular 15 MHz VC terminal, DL allocations at resource 652 and UL allocations at resource 656 , which may include edge subcarrier groups of PC 608 and PC 612 .
The base station 104 may also use individual PCs to communicate with legacy terminals. In this embodiment, e.g., 10 MHz legacy terminals may communicate with the base station 104 on PC 608 . The base station 104 may communicate, to a particular 10 MHz legacy terminal, DL allocations at resource 660 and UL allocations at resource 664 . It may be noted that communications between the base station 104 and the legacy terminal may not use the edge subcarrier groups of the PC 608 . However, these same edge subcarrier groups of PC 608 may be used for communications between the base station 104 and VC terminals without adversely affecting the communications with the legacy terminal.
Dividing an assigned bandwidth into various PCs, which may or may not have the same bandwidths, and utilizing the different PCs in various combinations to provide a variety of virtual carriers, may allow base stations endowed with teachings of this disclosure to scale communications to terminals configured to operate on any number of different bandwidths.
In some embodiments, one or more of the PCs of a virtual carrier may be used as a data only pipe. For example, in VC1 control and signaling information may be transmitted in PC 608 while the entire spectrum of PC 612 is reserved for data communications. However, if a PC is being used to communicate with a legacy terminal, some amount of control and signaling information may be desired in said PC.
FIG. 7 illustrates a multicarrier transmission being processed with and without reuse of edge subcarriers in accordance with an embodiment of the present disclosure. Referring to FIG. 7( a ) , a virtual carrier, including PCs 704 and 708 , may be used for transmissions to a VC terminal and PC 704 may be used for transmissions to a legacy terminal. Each of the PCs 704 and 708 may have 10 MHz bands. Data may be distributed among the PCs according to a partial usage subchannelization (PUSC) scheme with each PC having 841 subcarriers (not including edge carrier groups) over a 9.1984 MHz band.
In order to align the two PCs, the center frequency of PC 708 may be shifted by 3.125 KHz, which may result in the center frequencies of the two bands being 9.996875 MHz apart. The value of this frequency shift is purely exemplary and may be adjusted in various embodiments according to, e.g., carrier bandwidth, subcarrier spacing, etc.
FIG. 7( b ) illustrates subcarriers 712 that represent the 841 subcarriers of the PC 704 , subcarriers 716 that represent the 73 guard subcarriers, and subcarriers 720 that correspond to the 841 subcarriers of the PC 708 . The legacy terminal may include a 10 MHz band selection filter 724 that corresponds to the PC 704 .
FIG. 7( c ) illustrates data tones that may result from the sampling of the subcarriers of FIG. 7( b ) when all of the subcarriers, including the subcarriers 716 , are used for data transmission in accordance with an embodiment of the present disclosure. In this embodiment, a common sampling rate of 11.2 MHz for a 10 MHz carrier is used.
FIG. 7( d ) illustrates data tones that may result from the sampling of the subcarriers of FIG. 7( b ) when the subcarriers 716 are not used for data transmission in accordance with an embodiment of the present disclosure.
As can be seen by FIGS. 7( c ) and 7( d ) , the values of the subcarriers that are used by the legacy terminal, e.g., subcarriers 712 , are not impacted regardless of whether or not the guard band subcarriers 716 are used.
Therefore, data transmissions to a legacy terminal will not be affected, even when the guard subcarriers of the PC 708 are used and the PC 708 is effectively shifted closer to the PC 704 due to the alignment processing.
FIG. 8 illustrates how teachings of various embodiments facilitate a flexible deployment and upgrading of network equipment in accordance with various embodiments of this disclosure. At an initial stage 804 , 20 MHz of assigned bandwidth may be configured into two 10 MHz bands. The first band may be designated a PC 808 to be used only for communications with legacy terminals. The other 10 MHz band may be reserved.
At deployment stage 812 , the formally reserved band may be configured as PC 816 to be used only for communications with VC terminals.
At deployment stage 820 , the legacy-only PC 808 may be configured as PC 824 to be used for communications with legacy and/or VC terminals. This stage may be similar to the embodiment discussed with reference to FIG. 6 .
At deployment stage 828 , the legacy/VC PC 824 may be configured as PC 832 to be used only for communications with VC terminals. In this embodiment, the 20 MHz bandwidth may thus be used as two different 10 MHz bands or one 20 MHz band for various VC terminals of the wireless communication environment.
FIG. 9 illustrates a computing device 900 capable of implementing a VC terminal in accordance with various embodiments. As illustrated, for the embodiments, computing device 900 includes processor 904 , memory 908 , and bus 912 , coupled to each other as shown. Additionally, computing device 900 includes storage 916 , and communication interfaces 920 , e.g., a wireless network interface card (WNIC), coupled to each other, and the earlier described elements as shown.
Memory 908 and storage 916 may include in particular, temporal and persistent copies of coding and mapping logic 924 , respectively. The coding and mapping logic 924 may include instructions that when accessed by the processor 904 result in the computing device 900 performing encoding/decoding and mapping operations described in conjunction with various VC terminals in accordance with embodiments of this disclosure. In particular, these coding and mapping operations may allow a VC terminal, e.g., base station 104 and/or mobile station 108 , to transmit and/or receive communications over virtual carriers as described herein.
In various embodiments, the memory 908 may include RAM, dynamic RAM (DRAM), static RAM (SRAM), synchronous DRAM (SDRAM), dual-data rate RAM (DDRRAM), etc.
In various embodiments, the processor 904 may include one or more single-core processors, multiple-core processors, controllers, application-specific integrated circuits (ASICs), etc.
In various embodiments, storage 916 may include integrated and/or peripheral storage devices, such as, but not limited to, disks and associated drives (e.g., magnetic, optical), universal serial bus (USB) storage devices and associated ports, flash memory, read-only memory (ROM), nonvolatile semiconductor devices, etc.
In various embodiments, storage 916 may be a storage resource physically part of the computing device 900 or it may be accessible by, but not necessarily a part of, the computing device 900 . For example, the storage 916 may be accessed by the computing device 900 over a network.
In various embodiments, computing device 900 may have more or less components, and/or different architectures.
Although certain embodiments have been illustrated and described herein for purposes of description of the preferred embodiment, it will be appreciated by those of ordinary skill in the art that a wide variety of alternate and/or equivalent embodiments or implementations calculated to achieve the same purposes may be substituted for the embodiments shown and described without departing from the scope of the present invention. This application is intended to cover any adaptations or variations of the embodiments discussed herein. Therefore, it is manifestly intended that embodiments in accordance with the present invention be limited only by the claims and the equivalents thereof. | Embodiments of the present invention provide a virtual multicarrier design for orthogonal frequency division multiple access communications. Other embodiments may be described and claimed. | 49,695 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of priority of U.S. Provisional Application Ser. No. 60/710,682, filed Aug. 22, 2005, having attorney docket no. 05542-613P01, entitled “SPECTRUM BASED ENDPOINTING FOR CHEMICAL MECHANICAL POLISHING.”
BACKGROUND
The present invention relates to generally to chemical mechanical polishing of substrates.
An integrated circuit is typically formed on a substrate by the sequential deposition of conductive, semiconductive, or insulative layers on a silicon wafer. One fabrication step involves depositing a filler layer over a non-planar surface and planarizing the filler layer. For certain applications, the filler layer is planarized until the top surface of a patterned layer is exposed. A conductive filler layer, for example, can be deposited on a patterned insulative layer to fill the trenches or holes in the insulative layer. After planarization, the portions of the conductive layer remaining between the raised pattern of the insulative layer form vias, plugs, and lines that provide conductive paths between thin film circuits on the substrate. For other applications, such as oxide polishing, the filler layer is planarized until a predetermined thickness is left over the non planar surface. In addition, planarization of the substrate surface is usually required for photolithography.
Chemical mechanical polishing (CMP) is one accepted method of planarization. This planarization method typically requires that the substrate be mounted on a carrier or polishing head. The exposed surface of the substrate is typically placed against a rotating polishing disk pad or belt pad. The polishing pad can be either a standard pad or a fixed abrasive pad. A standard pad has a durable roughened surface, whereas a fixed-abrasive pad has abrasive particles held in a containment media. The carrier head provides a controllable load on the substrate to push it against the polishing pad. A polishing slurry is typically supplied to the surface of the polishing pad. The polishing slurry includes at least one chemically reactive agent and, if used with a standard polishing pad, abrasive particles.
One problem in CMP is determining whether the polishing process is complete, i.e., whether a substrate layer has been planarized to a desired flatness or thickness, or when a desired amount of material has been removed. Overpolishing (removing too much) of a conductive layer or film leads to increased circuit resistance. On the other hand, underpolishing (removing too little) of a conductive layer leads to electrical shorting. Variations in the initial thickness of the substrate layer, the slurry composition, the polishing pad condition, the relative speed between the polishing pad and the substrate, and the load on the substrate can cause variations in the material removal rate. These variations cause variations in the time needed to reach the polishing endpoint. Therefore, the polishing endpoint cannot be determined merely as a function of polishing time.
SUMMARY
In one general aspect, the invention features an assembly for chemical mechanical polishing. The assembly includes a polishing pad having a polishing surface. The assembly includes a solid window situated in the polishing pad to provide optical access through the polishing pad. The solid window includes a first portion made from polyurethane and a second portion made from quartz. The first portion has a surface that is co planar with the polishing surface of the polishing pad.
In another general aspect, the invention features a polishing pad that includes a polishing layer having a top surface and a bottom surface. The pad includes an aperture having a first opening in the top surface and a second opening in the bottom surface. The top surface is a polishing surface. The pad includes a window that includes a first portion made of soft plastic and a crystalline or glass like second portion. The window is transparent to white light. The window is situated in the aperture so that the first portion plugs the aperture and the second portion is on a bottom side of the first portion, wherein the first portion acts a slurry-tight barrier.
In another general aspect, the invention features a method of making a polishing pad. The method includes placing mass of crystalline or glass like material in a mold of a polishing pad window, the mass being transparent to white light. The method includes dispensing a liquid precursor of a soft plastic material into the mold, the soft plastic material being transparent to white light. The method includes curing the liquid precursor to form a window that includes a first portion made of soft plastic material and a crystalline or glass like second portion. The method includes placing the window in a mold of a polishing pad. The method includes dispensing a liquid precursor of a polishing pad material into the mold of the polishing pad. The method includes curing the liquid precursor of the polishing pad material to produce the polishing pad, wherein the window is situated in the mold of the polishing pad so that, when the polishing pad is produced, the window is situated in the polishing pad so that the first portion acts a slurry-tight barrier.
In another general aspect, the invention features a method of making a polishing pad. The method includes placing mass of crystalline or glass like materials in a mold of a polishing pad window, the mass being transparent to white light. The method includes dispensing a liquid precursor of a soft plastic material into the mold, the soft plastic material being transparent to white light. The method includes curing the liquid precursor to form a window that includes a first portion made of soft plastic material and a crystalline or glass like second portion. The method includes forming a polishing layer that includes an aperture, the polishing layer having a top surface and a bottom surface, the aperture having a first opening in the top surface and a second opening in the bottom surface, the top surface being a polishing surface. The method includes inserting the window in the aperture, the window being situated in the aperture so that the first portion plugs the aperture and the second portion is on a bottom side of the first portion, wherein the first portion acts a slurry-tight barrier.
In another general aspect, the invention features a method of making a polishing pad. The method includes forming a first portion of a polishing pad window, the first portion having a recess and being transparent to white light. The method includes inserting a mass of crystalline or glass like material into the recess, the mass being transparent to white light. The method includes forming a polishing layer that includes an aperture, the polishing layer having a top surface and a bottom surface, the aperture having a first opening in the top surface and a second opening in the bottom surface, the top surface being a polishing surface. The method includes inserting the window in the aperture, the window being situated in the aperture so that the first portion plugs the aperture and the second portion is on a bottom side of the first portion, wherein the first portion acts a slurry-tight barrier.
As used in the instant specification, the term substrate can include, for example, a product substrate (e.g., which includes multiple memory or processor dies), a test substrate, a bare substrate, and a gating substrate. The substrate can be at various stages of integrated circuit fabrication, e.g., the substrate can be a bare wafer, or it can include one or more deposited and/or patterned layers. The term substrate can include circular disks and rectangular sheets.
Possible advantages of implementations of the invention can include one or more of the following. Endpoint determination can be made virtually without consideration of variations in polishing rate. Factors that affect polishing rate, for example, consumables, generally need not be considered. A flushing system can be less likely to dry out slurry on a substrate surface being polished. A polishing pad window can enhance the accuracy and/or precision of endpoint determination.
The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the invention will become apparent from the description, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a chemical mechanical polishing apparatus.
FIGS. 2A-2H show implementations of a polishing pad window.
FIG. 3 shows an implementation of a flushing system.
FIG. 4 shows an alternative implementation of the flushing system.
FIG. 5 is an overhead view of a polishing pad and shows locations where in-situ measurements are taken.
FIG. 6A shows a spectrum obtained from in-situ measurements.
FIG. 6B illustrates the evolution of spectra obtained from in-situ measurements as polishing progresses.
FIG. 7A shows a method for obtaining a target spectrum.
FIG. 7B shows a method for obtaining a reference spectrum.
FIGS. 8A and 8B show a method for endpoint determination.
FIGS. 9A and 9B show an alternative method for endpoint determination.
FIGS. 10A and 10B show another alternative method for endpoint determination.
FIG. 11 shows an implementation for determining an endpoint.
FIG. 12 illustrates peak-to-trough normalization of a spectrum.
Like reference numbers and designations in the various drawings indicate like elements.
DETAILED DESCRIPTION
FIG. 1 shows a polishing apparatus 20 operable to polish a substrate 10 . The polishing apparatus 20 includes a rotatable disk-shaped platen 24 , on which a polishing pad 30 is situated. The platen is operable to rotate about axis 25 . For example, a motor can turn a drive shaft 22 to rotate the platen 24 . The polishing pad 30 can be detachably secured to the platen 24 , for example, by a layer of adhesive. When worn, the polishing pad 30 can be detached and replaced. The polishing pad 30 can be a two-layer polishing pad with an outer polishing layer 32 and a softer backing layer 34 .
Optical access 36 through the polishing pad is provided by including an aperture (i.e., a hole that runs through the pad) or a solid window. The solid window can be secured to the polishing pad, although in some implementations the solid window can be supported on the platen 24 and project into an aperture in the polishing pad. The polishing pad 30 is usually placed on the platen 24 so that the aperture or window overlies an optical head 53 situated in a recess 26 of the platen 24 . The optical head 53 consequently has optical access through the aperture or window to a substrate being polished. The optical head is further described below.
The window can be, for example, a rigid crystalline or glassy material, e.g., quartz or glass, or a softer plastic material, e.g., silicone, polyurethane or a halogenated polymer (e.g., a fluoropolymer), or a combination of the materials mentioned. The window can be transparent to white light. If a top surface of the solid window is a rigid crystalline or glassy material, then the top surface should be sufficiently recessed from the polishing surface to prevent scratching. If the top surface is near and may come into contact with the polishing surface, then the top surface of the window should be a softer plastic material. In some implementations the solid window is secured in the polishing pad and is a polyurethane window, or a window having a combination of quartz and polyurethane. The window can have high transmittance, for example, approximately 80% transmittance, for monochromatic light of a particular color, for example, blue light or red light. The window can be sealed to the polishing pad 30 so that liquid does not leak through an interface of the window and the polishing pad 30 .
In one implementation, the window includes a rigid crystalline or glassy material covered with an outer layer of a softer plastic material. The top surface of the softer material can be coplanar with the polishing surface. The bottom surface of the rigid material can be coplanar with or recessed relative to the bottom surface of the polishing pad. In particular, if the polishing pad includes two layers, the solid window can be integrated into the polishing layer, and the bottom layer can have an aperture aligned with the solid window.
Assuming that the window includes a combination of a rigid crystalline or glassy material and a softer plastic material, no adhesive need be used to secure the two portions. For example, in one implementation, no adhesive is used to couple the polyurethane portion to the quartz portion of the window. Alternatively, an adhesive that is transparent to white light can be used or an adhesive can be applied so that light passing through the window does not pass through the adhesive. By way of example, the adhesive can be applied only to the perimeter of the interface between the polyurethane and quartz portion. A refractive index gel can be applied to a bottom surface of the window.
A bottom surface of the window can optionally include one or more recesses. A recess can be shaped to accommodate, for example, an end of an optical fiber cable or an end of an eddy current sensor. The recess allows the end of the optical fiber cable or the end of the eddy current sensor to be situated at a distance, from a substrate surface being polished, that is less than a thickness of the window. With an implementation in which the window includes a rigid crystalline portion or glass like portion and the recess is formed in such a portion by machining, the recess is polished so as to remove scratches caused by the machining. Alternatively, a solvent and/or a liquid polymer can be applied to the surfaces of the recess to remove scratches caused by machining. The removal of scratches usually caused by machining reduces scattering and can improve the transmittance of light through the window.
FIGS. 2A-2H show various implementations of the window. As shown in FIG. 2A , the window can have two portions, a polyurethane portion 202 and a quartz portion 204 . The portions are layers, with the polyurethane portion 202 situated on top of the quartz portion 204 . The window can be situated in the polishing pad so that the top surface 206 of the polyurethane layer is coplanar with a polishing surface 208 of the polishing pad.
As shown in FIG. 2B , the polyurethane portion 202 can have a recess in which the quartz portion is situated. A bottom surface 210 of the quartz portion is exposed.
As shown in FIG. 2C , the polyurethane portion 202 can include projections, for example, projection 212 , that project into the quartz portion 204 . The projections can act to reduce the likelihood that the polyurethane portion 202 will be pulled away from the quartz portion 204 due to friction from the substrate or retaining ring.
As shown in FIG. 2D , the interface between the polyurethane portion 202 and quartz portion 204 can be a rough surface. Such a surface can improve the strength of the coupling of the two portions of the window, also reducing the likelihood the polyurethane portion 202 will be pulled away from the quartz portion 204 due to friction from the substrate or retaining ring.
As shown in FIG. 2E , the polyurethane portion 202 can have non-uniform thickness. The thickness at a location that would be in the path 214 of a light beam is less than the thickness at a location that would not be in the path 214 of the light beam. By way of example, thickness t 1 is less than thickness t 2 . Alternatively, the thickness can be less at the edges of the window.
As shown in FIG. 2F , the polyurethane portion 202 can be attached to the quartz portion 204 by use of an adhesive 216 . The adhesive can be applied so that it would not be in the path 214 of the light beam.
As shown in FIG. 2G , the polishing pad can include a polishing layer and a backing layer. The polyurethane portion 202 extends through the polishing layer and at least partially into the backing layer. The hole in the backing layer can be larger in size than the hole in the polishing layer, and the section of the polyurethane in the backing layer can be wider than the section of the polyurethane in the polishing layer. The polishing layer thus provides a lip 218 which overhangs the window and which can act to resist a pulling of the polyurethane portion 202 away from the quartz portion 204 . The polyurethane portion 202 conforms to the holes of the layers of the polishing pad.
As shown in FIG. 2H , refractive index gel 220 can be applied to the bottom surface 210 of the quartz portion 204 so as to provide a medium for light to travel from a fiber cable 222 to the window. The refractive index gel 220 can fill the volume between the fiber cable 222 and the quartz portion 204 and can have a refractive index that matches or is between the indices of refraction of the fiber cable 222 and the quartz portion 204 .
In implementations where the window includes both quartz and polyurethane portions, the polyurethane portion should have a thickness so that, during the life time of the polishing pad, the polyurethane portion will not be worn so as to expose the quartz portion. The quartz can be recessed from the bottom surface of the polishing pad, and the fiber cable 222 can extend partially into the polishing pad.
The above described window and polishing pad can be manufactured using a variety of techniques. The polishing pad's backing layer 34 can be attached to its outer polishing layer 32 , for example, by adhesive. The aperture that provides optical access 36 can be formed in the pad 30 , e.g., by cutting or by molding the pad 30 to include the aperture, and the window can be inserted into the aperture and secured to the pad 30 , e.g., by an adhesive. Alternatively, a liquid precursor of the window can be dispensed into the aperture in the pad 30 and cured to form the window. Alternatively, a solid transparent element, e.g., the above described crystalline or glass like portion, can be positioned in liquid pad material, and the liquid pad material can be cured to form the pad 30 around the transparent element. In either of the later two cases, a block of pad material can be formed, and a layer of polishing pad with the molded window can be scythed from the block.
With an implementation in which the window includes a crystalline or glass like first portion and a second portion made of soft plastic material, the second portion can be formed in the aperture of the pad 30 by applying the described liquid precursor technique. The first portion can then be inserted. If the first portion is inserted before the liquid precursor of the second portion is cured, then curing can bond the first and second portions. If the first portion is inserted after the liquid precursor is cured, then the first and second potions can be secured by using an adhesive.
The polishing apparatus 20 can include a flushing system to improve light transmission through the optical access 36 . There are different implementations of the flushing system. With implementations of the polishing apparatus 20 in which the polishing pad 30 includes an aperture instead of a solid window, the flushing system is implemented to provide a laminar flow of a fluid, e.g., a gas or liquid, across a top surface of the optical head 53 . (The top surface can be a top surface of a lens included in the optical head 53 .) The laminar flow of fluid across the top surface of the optical head 53 can sweep opaque slurry out of the optical access and/or prevent slurry from drying on the top surface and, consequently, improves transmission through the optical access. With implementations in which the polishing pad 30 includes a solid window instead of an aperture, the flushing system is implemented to direct a flow of gas at a bottom surface of the window. The flow of gas can prevent condensation from forming at the solid window's bottom surface which would otherwise impede optical access.
FIG. 3 shows an implementation of the laminar-flow flushing system. The flushing system includes a gas source 302 , a delivery line 304 , a delivery nozzle 306 , a suction nozzle 308 , a vacuum line 310 , and a vacuum source 312 . The gas source 302 and vacuum source can be configured so that they can introduce and suction a same or a similar volume of gas. The delivery nozzle 306 is situated so that the laminar flow of gas is directed across the transparent top surface 314 of the in-situ monitoring module and not directed at the substrate surface being polished. Consequently, the laminar flow of gas does not dry out slurry on a substrate surface being polished, which can undesirably affect polishing.
FIG. 4 shows an implementation of the flushing system for preventing the formation of condensation on a bottom surface of the solid window. The system reduces or prevents the formation of condensation at the bottom surface of the polishing pad window. The system includes a gas source 402 , a delivery line 404 , a delivery nozzle 406 , a suction nozzle 408 , a vacuum line 410 , and a vacuum source 412 . The gas source 402 and vacuum source can be configured so that they can introduce and suction a same or a similar volume of gas. The delivery nozzle 406 is situated so that the flow of gas is directed at the bottom surface window in the polishing pad 30 .
In one implementation that is an alternative to the implementation of FIG. 4 , the flushing system does not include a vacuum source or line. In lieu of these components, the flushing system includes a vent formed in the platen so that the gas introduced into the space underneath the solid window can be exhausted to a side of the platen or, alternatively, to any other location in the polishing apparatus that can tolerate moisture.
The above described gas source and vacuum source can be located away from the platen so that they do not rotate with the platen. In this case, a rotational coupler for convey gas is included each of the supply line and the vacuum line.
Returning to FIG. 1 , the polishing apparatus 20 includes a combined slurry/rinse arm 39 . During polishing, the arm 39 is operable to dispense slurry 38 containing a liquid and a pH adjuster. Alternative, the polishing apparatus includes a slurry port operable to dispense slurry onto polishing pad 30 .
The polishing apparatus 20 includes a carrier head 70 operable to hold the substrate 10 against the polishing pad 30 . The carrier head 70 is suspended from a support structure 72 , for example, a carousel, and is connected by a carrier drive shaft 74 to a carrier head rotation motor 76 so that the carrier head can rotate about an axis 71 . In addition, the carrier head 70 can oscillate laterally in a radial slot formed in the support structure 72 . In operation, the platen is rotated about its central axis 25 , and the carrier head is rotated about its central axis 71 and translated laterally across the top surface of the polishing pad.
The polishing apparatus also includes an optical monitoring system, which can be used to determine a polishing endpoint as discussed below. The optical monitoring system includes a light source 51 and a light detector 52 . Light passes from the light source 51 , through the optical access 36 in the polishing pad 30 , impinges and is reflected from the substrate 10 back through the optical access 36 , and travels to the light detector 52 .
A bifurcated optical cable 54 can be used to transmit the light from the light source 51 to the optical access 36 and back from the optical access 36 to the light detector 52 . The bifurcated optical cable 54 can include a “trunk” 55 and two “branches” 56 and 58 .
As mentioned above, the platen 24 includes the recess 26 , in which the optical head 53 is situated. The optical head 53 holds one end of the trunk 55 of the bifurcated fiber cable 54 , which is configured to convey light to and from a substrate surface being polished. The optical head 53 can include one or more lenses or a window overlying the end of the bifurcated fiber cable 54 (e.g., as shown in FIG. 3 ). Alternatively, the optical head 53 can merely hold the end of the trunk 55 adjacent the solid window in the polishing pad. The optical head 53 can hold the above-described nozzles of the flushing system. The optical head 53 can be removed from the recess 26 as required, for example, to effect preventive or corrective maintenance.
The platen includes a removable in-situ monitoring module 50 . The in-situ monitoring module 50 can include one or more of the following: the light source 51 , the light detector 52 , and circuitry for sending and receiving signals to and from the light source 51 and light detector 52 . For example, the output of the detector 52 can be a digital electronic signal that passes through a rotary coupler, e.g., a slip ring, in the drive shaft 22 to the controller for the optical monitoring system. Similarly, the light source can be turned on or off in response to control commands in digital electronic signals that pass from the controller through the rotary coupler to the module 50 .
The in-situ monitoring module can also hold the respective ends of the branch portions 56 and 58 of the bifurcated optical fiber 54 . The light source is operable to transmit light, which is conveyed through the branch 56 and out the end of the trunk 55 located in the optical head 53 , and which impinges on a substrate being polished. Light reflected from the substrate is received at the end of the trunk 55 located in the optical head 53 and conveyed through the branch 58 to the light detector 52 .
In one implementation, the bifurcated fiber cable 54 is a bundle of optical fibers. The bundle includes a first group of optical fibers and a second group of optical fibers. An optical fiber in the first group is connected to convey light from the light source 51 to a substrate surface being polished. An optical fiber in the second group is connected to received light reflecting from the substrate surface being polished and convey the received light to a light detector. The optical fibers can be arranged so that the optical fibers in the second group form an X-like shape that is centered on the longitudinal axis of the bifurcated optical fiber 54 (as viewed in a cross section of the bifurcated fiber cable 54 ). Alternatively, other arrangements can be implemented. For example, the optical fibers in the second group can form V-like shapes that are mirror images of each other. A suitable bifurcated optical fiber is available from Verity Instruments, Inc. of Carrollton, Tex.
There is usually an optimal distance between the polishing pad window and the end of the trunk 55 of bifurcated fiber cable 54 proximate to the polishing pad window. The distance can be empirically determined and is affected by, for example, the reflectivity of the window, the shape of the light beam emitted from the bifurcated fiber cable, and the distance to the substrate being monitored. In one implementation, the bifurcated fiber cable is situated so that the end proximate to the window is as close as possible to the bottom of the window without actually touching the window. With this implementation, the polishing apparatus 20 can include a mechanism, e.g., as part of the optical head 53 , that is operable to adjust the distance between the end of the bifurcated fiber cable 54 and the bottom surface of the polishing pad window. Alternatively, the proximate end of the bifurcated fiber cable is embedded in the window.
The light source 51 is operable to emit white light. In one implementation, the white light emitted includes light having wavelengths of 200-800 nanometers. A suitable light source is a xenon lamp or a xenon-mercury lamp.
The light detector 52 can be a spectrometer. A spectrometer is basically an optical instrument for measuring properties of light, for example, intensity, over a portion of the electromagnetic spectrum. A suitable spectrometer is a grating spectrometer. Typical output for a spectrometer is the intensity of the light as a function of wavelength.
Optionally, the in-situ monitoring module 50 can include other sensor elements. The in-situ monitoring module 50 can include, for example, eddy current sensors, lasers, light emitting diodes, and photodetectors. With implementations in which the in-situ monitoring module 50 includes eddy current sensors, the module 50 is usually situated so that a substrate being polished is within working range of the eddy current sensors.
The light source 51 and light detector 52 are connected to a computing device operable to control their operation and to receive their signals. The computing device can include a microprocessor situated near the polishing apparatus, e.g., a personal computer. With respect to control, the computing device can, for example, synchronize activation of the light source 51 with the rotation of the platen 24 . As shown in FIG. 5 , the computer can cause the light source 51 to emit a series of flashes starting just before and ending just after the substrate 10 passes over the in-situ monitoring module. (Each of points 501 - 511 depicted represents a location where light from the in-situ monitoring module impinged and reflected off.) Alternatively, the computer can cause the light source 51 to emit light continuously starting just before and ending just after the substrate 10 passes over the in-situ monitoring module.
With respect to receiving signals, the computing device can receive, for example, a signal that carries information describing a spectrum of the light received by the light detector 52 . FIG. 6A shows examples of a spectrum measured from light that is emitted from a single flash of the light source and that is reflected from the substrate. Spectrum 602 is measured from light reflected from a product substrate. Spectrum 604 is measured from light reflected from a base silicon substrate (which is a wafer that has only a silicon layer). Spectrum 606 is from light received by the optical head 53 when there is no substrate situated over the optical head 53 . Under this condition, referred to in the present specification as a dark condition, the received light is typically ambient light.
The computing device can process the above-described signal to determine an endpoint of a polishing step. Without being limited to any particular theory, the spectra of light reflected from the substrate 10 evolve as polishing progresses. FIG. 6B provides an example of the evolution as polishing of a film of interest progresses. The different lines of spectrum represent different times in the polishing. As can be seen, properties of the spectrum of the reflected light changes as a thickness of the film changes, and particular spectrums are exhibited by particular thicknesses of the film. The computing device can execute logic that determines, based on one or more of the spectra, when an endpoint has been reached. The one or more spectra on which an endpoint determination is based can include a target spectrum, a reference spectrum, or both.
As used in the instant specification, a target spectrum refers to a spectrum exhibited by the white light reflecting from a film of interest when the film of interest has a target thickness. By way of example, a target thickness can be 1, 2, or 3 microns. Alternatively, the target thickness can be zero, for example, when the film of interest is cleared so that an underlying film is exposed.
FIG. 7A shows a method 700 for obtaining a target spectrum. Properties of a substrate with the same pattern as the product substrate are measured (step 702 ). The substrate which is measured is referred to in the instant specification as a “set-up” substrate. The set-up substrate can simply be a substrate which is similar or the same to the product substrate, or the set-up substrate could be one substrate from a batch. The properties can include a pre-polished thickness of a film of interest at a particular location of interest on the substrate. Typically, the thicknesses at multiple locations are measured. The locations are usually selected so that a same type of die feature is measured for each location. Measurement can be performed at a metrology station.
The set-up substrate is polished in accordance with a polishing step of interest and spectra of white light reflecting off a substrate surface being polished are collected during polishing (step 704 ). Polishing and spectra collection can be performed at the above described polishing apparatus. Spectra are collected by the in-situ monitoring system during polishing. The substrate is overpolished, i.e., polished past an estimated endpoint, so that the spectrum of the light that reflected from the substrate when the target thickness is achieved can be obtained.
Properties of the overpolished substrate are measured (step 706 ). The properties include post-polished thicknesses of the film of interest at the particular location or locations used for the pre-polish measurement.
The measured thicknesses and the collected spectra are used to select, from among the collected spectra, a spectrum determined to be exhibited by a thickness of interest (step 708 ). In particular, linear interpolation can be performed using the measured pre-polish film thickness and post-polish substrate thicknesses to determine which of the spectra was exhibited when the target film thickness was achieved. The spectrum determined to be the one exhibited when the target thickness was achieved is designated to be the target spectrum for the batch of substrates.
Optionally, the spectra collected are processed to enhance accuracy and/or precision. The spectra can be processed, for example: to normalize them to a common reference, to average them, and/or to filter noise from them. Particular implementations of these processing operations are described below.
As used in the instant specification, a reference spectrum refers to a spectrum that is associated with a target film thickness. A reference spectrum is usually empirically selected for particular endpoint determination logic so that the target thickness is achieved when the computer device calls endpoint by applying the particular spectrum-based endpoint logic. The reference spectrum can be iteratively selected, as will be described below in reference to FIG. 7B . The reference spectrum is usually not the target spectrum. Rather, the reference spectrum is usually the spectrum of the light reflected from the substrate when the film of interest has a thickness greater than the target thickness.
FIG. 7B shows a method 701 for selecting a reference spectrum for a particular target thickness and particular spectrum-based endpoint determination logic. A set up substrate is measured and polished as described above in steps 702 - 706 (step 703 ). In particular, spectra collected and the time at which each collected spectrum is measured is stored.
A polishing rate of the polishing apparatus for the particular set-up substrate is calculated (step 705 ). The average polishing rate PR can be calculated by using the pre and post-polished thicknesses T 1 , T 2 , and the actual polish time, PT, e.g., PR=(T 2 −T 1 )/PT.
An endpoint time is calculated for the particular set-up substrate to provide a calibration point to test the reference spectrum, as discussed below (step 707 ). The endpoint time can be calculated based on the calculated polish rate PR, the pre-polish starting thickness of the film of interest, ST, and the target thickness of the film of interest, TT. The endpoint time can be calculated as a simple linear interpolation, assuming that the polishing rate is constant through the polishing process, e.g., ET=(ST−TT)/PR.
Optionally, the calculated endpoint time can be evaluated by polishing another substrate of the batch of patterned substrates, stopping polishing at the calculated endpoint time, and measuring the thickness of the film of interest. If the thickness is within a satisfactory range of the target thickness, then the calculated endpoint time is satisfactory. Otherwise, the calculated endpoint time can be re-calculated.
One of the collected spectra is selected and designated to be the reference spectrum (step 709 ). The spectrum selected is a spectrum of light reflected from the substrate when the film of interest has a thickness greater than and is approximately equal to the target thickness.
The particular endpoint determination logic is executed in simulation using the spectra collected for the set-up substrate and with the selected spectrum designated to be the reference spectrum (step 711 ). Execution of the logic yields an empirically derived but simulated endpoint time that the logic has determined to be the endpoint.
The empirically derived but simulated endpoint time is compared to the calculated endpoint time (step 713 ). If the empirically derived endpoint time is within a threshold range of the calculated endpoint time, then the currently selected reference spectrum is known to generate a result that matches the calibration point. Thus, when the endpoint logic is executed using the reference spectrum in a run-time environment, the system should reliably detect an endpoint at the target thickness. Therefore, the reference spectrum can be kept as the reference spectrum for run time polishing of the other substrates of the batch (step 718 ). Otherwise, steps 709 and 711 are repeated as appropriate.
Optionally, variables other than the selected spectrum can be changed for each iteration (i.e., each performance of steps 709 and 711 ). For example, the above-mentioned processing of the spectra (for example, filter parameters) and/or a threshold range from a minimum of a difference trace can be changed. The difference trace and the threshold range of a minimum of the difference trace are described below.
FIG. 8A shows a method 800 for using spectrum-based endpoint determination logic to determine an endpoint of a polishing step. Another substrate of the batch of patterned substrates is polished using the above-described polishing apparatus (step 802 ). At each revolution of the platen, the following steps are performed.
One or more spectra of white light reflecting off a substrate surface being polished are measured to obtain one or more current spectra for a current platen revolution (step 804 ). The one or more spectra measured for the current platen revolution are optionally processed to enhance accuracy and/or precision as described above in reference to FIG. 7A and as described below in reference to FIG. 11 . If only one spectrum is measured, then the one spectrum is used as the current spectrum. If more than one current spectra is measured for a platen revolution, then they are grouped, averaged within each group, and the averages are designated to be current spectra. The spectra can be grouped by radial distance from the center of the substrate. By way of example, a first current spectrum can be obtained from spectra measured as points 502 and 510 ( FIG. 5 ), a second current spectrum can be obtained from spectra measured at points 503 and 509 , a third current spectra can be obtained from spectra measured at points 504 and 508 , and so forth. The spectra measured at points 502 and 510 are averaged to obtain a first current spectrum for the current platen revolution. The spectra measured at points 503 and 509 are averaged to obtain a second current spectrum for the current platen revolution. The spectra measured at points 504 and 508 are averaged to obtain a third current spectrum for the current platen revolution.
A difference between the one or more current spectra and a reference spectrum is calculated (step 806 ). The reference spectrum can be obtained as described above in reference to FIG. 7B . In one implementation, the difference is a sum of differences in intensities over a range of wavelengths. That is,
Difference = ∑ λ = a b abs ( I current ( λ ) - I reference ( λ ) )
where a and b are the lower limit and upper limit of the range of wavelengths of a spectrum, respectively, and I current (λ) and I reference (λ) are the intensity of a current spectra and the intensity of the target spectra for a given wavelength, respectively.
Each calculated difference is appended to a difference trace (step 808 ). The difference trace is generally a plot of the calculated difference. The difference trace is updated at least once per platen revolution. (When multiple current spectra are obtained for each platen revolution, the difference trace can be updated more than once per platen revolution.)
Optionally, the difference trace can be processed, for example, smoothing the difference trace by filtering out a calculated difference that deviates beyond a threshold from preceding one or more calculated differences.
Whether the difference trace is within a threshold value of a minimum is determined (step 810 ). After the minimum has been detected, the endpoint is called when the different trace begins to rise past a particular threshold value of the minimum. Alternatively, the endpoint can be called based on the slope of the difference trace. In particular, the slope of the difference trace approaches and becomes zero at the minimum of the difference trace. The endpoint can be called when the slope of the difference trace is within a threshold range of the slope that is near zero.
Optionally, window logic can be applied to facilitate the determination of step 808 . Window logic suitable for use is described in commonly assigned U.S. Pat. Nos. 5,893,796 and 6,296,548, which are incorporated by reference.
If the difference trace is NOT determined to have reached a threshold range of a minimum, polishing is allowed to continue and steps 804 , 806 , 808 , and 810 are repeated as appropriate. Otherwise, an endpoint is called and polishing is stopped (step 812 ).
FIG. 8B illustrates the above described method for determining endpoint. Trace 801 is the raw difference trace. Trace 803 is the smoothed difference trace. Endpoint is called when the smoothed difference trace 803 reaches a threshold value 805 above the minimum 807 .
As an alternative to using a reference spectrum, a target spectrum can be used in the method 800 . The difference calculation would be between a current spectrum and the target spectrum, and endpoint would be determined when the difference trace reaches a minimum.
FIG. 9A shows an alterative method 900 for using a spectrum-based endpoint determination logic to determine an endpoint of a polishing step. A set-up substrate is polished and a target spectrum and reference spectrum are obtained (step 902 ). These spectra can be obtained as described above in reference to FIGS. 7A and 7B .
A target difference is calculated (step 904 ). The target difference is the difference between the reference spectrum and the target spectrum and can be calculated using the above-described difference equation.
Polishing of another substrate of the batch of substrates is started (step 906 ). The following steps are performed for each platen revolution during polishing. One or more spectra of white light reflecting off a substrate surface being polished are measured to obtain one or more current spectra for a current platen revolution (step 908 ). A difference between the current one or more spectra and the reference spectrum is calculated (step 910 ). The calculated difference or differences (if there are more than one current spectrum) are appended to a difference trace (step 912 ). Whether the difference trace is within a threshold range of the target difference is determined (step 914 ). If the difference trace is NOT determined to have reached a threshold range of the target difference, polishing is allowed to continue and steps 908 , 910 , 912 , and 914 are repeated as appropriate. Otherwise, an endpoint is called and polishing is stopped (step 916 ).
FIG. 9B illustrates the above described method for determining endpoint. Trace 901 is the raw difference trace. Trace 903 is the smoothed difference trace. Endpoint is called when the smooth difference trace 903 is within a threshold range 905 of a target difference 907 .
FIG. 10A shows another method 1000 for determining an endpoint of a polishing step. A reference spectrum is obtained (step 1002 ). The reference spectrum is obtained as described above in reference to FIG. 7B .
The spectra collected from the process of obtaining the reference spectrum are stored in a library (step 1004 ). Alternatively, the library can include spectra that are not collected but theoretically generated. The spectra, including the reference spectrum, are indexed so that each spectrum has a unique index value. The library can be implemented in memory of the computing device of the polishing apparatus.
A substrate from the batch of substrates is polished, and the following steps are performed for each platen revolution. One or more spectra are measured to obtain a current spectra for a current platen revolution (step 1006 ). The spectra are obtained as described above. The spectra stored in the library which best fits the current spectra is determined (step 1008 ). The index of the library spectrum determined to best fits the current spectra is appended to an endpoint index trace (step 1010 ). Endpoint is called when the endpoint trace reaches the index of the reference spectrum (step 1012 ).
FIG. 10B illustrates the above described method for determining endpoint. Trace 1014 is the raw index trace. Trace 1016 is the smoothed difference trace. Line 1018 represents the index value of the reference spectrum. Multiple current spectra can be obtained in each sweep of the optical head beneath the substrate, e.g., a spectra for each radial zone on the substrate being tracked, and an index trace can be generated for each radial zone.
FIG. 11 shows an implementation for determining an endpoint during a polishing step. For each platen revolution, the following steps are performed. Multiple raw spectra of white light reflecting off a substrate surface being polished are measured (step 1102 ).
Each measured raw spectra is normalized to remove light reflections contributed by mediums other than the film or films of interest (step 1104 ). Normalization of spectra facilitates their comparison to each other. Light reflections contributed by media other than the film or films of interest include light reflections from the polishing pad window and from the base silicon layer of the substrate. Contributions from the window can be estimated by measuring the spectrum of light received by the in-situ monitoring system under a dark condition (i.e., when no substrates are placed over the in-situ monitoring system). Contributions from the silicon layer can be estimated by measuring the spectrum of light reflecting of a bare silicon substrate. The contributions are usually obtained prior to commencement of the polishing step.
A measured raw spectrum is normalized as follows:
normalized spectrum=( A −Dark)/( Si −Dark)
where A is the raw spectrum, Dark is the spectrum obtained under the dark condition, and Si is the spectrum obtained from the bare silicon substrate.
Optionally, the collected spectra can be sorted based on the region of the pattern that has generated the spectrum, and spectra from some regions can be excluded from the endpoint calculation. In particular, spectra that are from light reflecting off scribe lines can be removed from consideration (step 1106 ). Different regions of a pattern substrate usually yield different spectra (even when the spectra were obtained at a same point of time during polishing). For example, a spectrum of the light reflecting off a scribe line in a substrate is different from the spectrum of the light reflecting off an array of the substrate. Because of their different shapes, use of spectra from both regions of the pattern usually introduces error into the endpoint determination. However, the spectra can be sorted based on their shapes into a group for scribe lines and a group for arrays. Because there is often greater variation in the spectra for scribe lines, usually these spectra can be excluded from consideration to enhance precision.
A subset of the spectra processed thus far is selected and averaged (step 1108 ). The subset consists of the spectra obtained from light reflecting off the substrate at points of a region on the substrate. The region can be, for example, region 512 or region 413 ( FIG. 5 ).
Optionally, a high-pass filter is applied to the measured raw spectra (step 1110 ). Application of the high pass filter typically removes low frequency distortion of the average of the subset of spectra. The high-pass filter can be applied to the raw spectra, their average, or to both the raw spectra and their average.
The average is normalized so that its amplitude is the same or similar to the amplitude of the reference spectrum (step 1112 ). The amplitude of a spectrum is the peak-to-trough value of the spectrum. Alternatively, the average is normalized so that its reference spectrum is the same or similar to a reference amplitude to which the reference spectrum has also been normalized.
A difference between the normalized average and a reference spectrum is calculated (step 1114 ). The reference spectrum is obtained as described in reference to FIG. 7B . The difference is calculated using the above-described equation for calculating differences between spectra.
A difference trace is updated with the current difference (step 1116 ). The difference trace exhibits calculated differences between normalized averages and the reference spectrum as a function of time (or platen revolution).
A median and low-pass filter is applied to the updated difference trace (step 1118 ). Application of these filters typically smoothes the trace (by reducing or eliminating spikes in the trace).
Endpoint determination is performed based on the updated and filtered difference trace (step 1120 ). The determination is made based on when the difference trace reaches a minimum. The above described window logic is used to make the determination.
More generally, the signal processing steps of steps 1104 - 1112 can be used to improve endpoint determination procedures. For example, instead of generation of a difference trace, the normalized average spectra could be used to select a spectra from a library to generate an index trace, as described above in reference to FIG. 10A .
FIG. 12 illustrates the normalization of step 1112 . As can be seen, only a portion of a spectrum (or an average of spectra) is considered for normalization. The portion considered is referred to in the instant specification as a normalization range and, furthermore, can be user selectable. Normalization is effected so that the highest point and the lowest point in the normalization range are normalized to 1 and 0, respectively. The normalization is calculated as follows:
g =(1−0)/( r max −r min ) h =1 −r max ·g N=R·g+h
where, g is a gain, h is an offset, r max is the highest value in the normalization range, r min is the lowest value in the normalization range, N is the normalized spectrum, and R is the pre normalized spectrum.
Embodiments of the invention and all of the functional operations described in this specification can be implemented in digital electronic circuitry, or in computer software, firmware, or hardware, including the structural means disclosed in this specification and structural equivalents thereof, or in combinations of them. Embodiments of the invention can be implemented as one or more computer program products, i.e., one or more computer programs tangibly embodied in an information carrier, e.g., in a machine-readable storage device or in a propagated signal, for execution by, or to control the operation of, data processing apparatus, e.g., a programmable processor, a computer, or multiple processors or computers. A computer program (also known as a program, software, software application, or code) can be written in any form of programming language, including compiled or interpreted languages, and it can be deployed in any form, including as a stand-alone program or as a module, component, subroutine, or other unit suitable for use in a computing environment. A computer program does not necessarily correspond to a file. A program can be stored in a portion of a file that holds other programs or data, in a single file dedicated to the program in question, or in multiple coordinated files (e.g., files that store one or more modules, sub-programs, or portions of code). A computer program can be deployed to be executed on one computer or on multiple computers at one site or distributed across multiple sites and interconnected by a communication network.
The processes and logic flows described in this specification can be performed by one or more programmable processors executing one or more computer programs to perform functions by operating on input data and generating output. The processes and logic flows can also be performed by, and apparatus can also be implemented as, special purpose logic circuitry, e.g., an FPGA (field programmable gate array) or an ASIC (application-specific integrated circuit).
The above described polishing apparatus and methods can be applied in a variety of polishing systems. Either the polishing pad, or the carrier head, or both can move to provide relative motion between the polishing surface and the substrate. For example, the platen may orbit rather than rotate. The polishing pad can be a circular (or some other shape) pad secured to the platen. Some aspects of the endpoint detection system may be applicable to linear polishing systems, e.g., where the polishing pad is a continuous or a reel-to-reel belt that moves linearly. The polishing layer can be a standard (for example, polyurethane with or without fillers) polishing material, a soft material, or a fixed-abrasive material. Terms of relative positioning are used; it should be understood that the polishing surface and substrate can be held in a vertical orientation or some other orientation.
Particular embodiments of the invention have been described. Other embodiments are within the scope of the following claims. For example, the actions recited in the claims can be performed in a different order and still achieve desirable results. | Methods and apparatus for providing a chemical mechanical polishing pad. The pad includes a polishing layer having a top surface and a bottom surface. The pad includes an aperture having a first opening in the top surface and a second opening in the bottom surface. The top surface is a polishing surface. The pad includes a window that includes a first portion made of soft plastic and a crystalline or glass like second portion. The window is transparent to white light. The window is situated in the aperture so that the first portion plugs the aperture and the second portion is on a bottom side of the first portion, wherein the first portion acts a slurry-tight barrier. | 56,183 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a device for calculating, storing and displaying the score of a competitive sport or game that is similar to tennis.
2. Description of the Prior Art
In any competitive game, it is of great value to keep a reliable record of scores as the game progresses. In games that are generally regarded as spectator sports, it is often worthwhile for owners of the playing facilities to invest in large scoreboards so that the results and timing of a game are immediately visible to spectators, players and officials alike. But many sports are played only in the presence of the players, and costly scoreboard arrangements are not economically feasible.
Some games, such as tennis, lawn tennis, table tennis and volleyball have scoring systems that are not as straightforward as simply counting a point score until a particular value is reached. In each of the games cited, there is at some point in the game a condition in which a player must achieve a certain number of points greater than those of his opponent in order to win and terminate the game.
The two conditions described above indicate a need for a device which may be used without costly construction, without hindering the physical activities of the players, and with the ability to construct a score sequence that goes beyond ordinary point counting.
U.S. Pat. No. 3,254,433 to Saile and Saile describes a partial but useful approach to these problems, wherein a scoring device mountable on the fence of a tennis court contains an actuating mechanism on its front panel, which indexes a score displaying mechanism whenever a tennis ball is thrown at it. This allows the scores to be displayed without requiring either player to carry a bulky scorekeeping device, and without participation by any third party. It does not, however, teach means for identifying and calculating the existence of a "deuce" or "advantage" condition as is frequent in tennis; such a condition may be displayed, but requires the player to strike the target panel more than once to position the display device to the proper score.
A comprehensive solution to the needs of scoring a game such as tennis would necessarily involve a device that may be adapted for either public display (as in a scoreboard), or which may be small and light enough for the player to wear without discomfort or restriction of his playing skill. It should also respond to any new point scored in tennis or similar games without requiring the player to divert his consciousness from the actual playing of the game, and hence should be fully automatic in its calculation of a new score, as well as in its ability to identify the winning of a game and the subsequent increase in a player's set score.
In addition to the scoring of games, there are other features which are incidental to the playing of a game and which would render such a device much more useful, explicitly to the tennis player. Some games including tennis require the exchange of sides of the playing court after a certain number of games are played, to insure fairness in the presence of local playing conditions such as sunlight or wind. Accordingly, it is an object of the present invention to provide a court change indication based on a particular class of scoring states.
When several players must share the same facilities, local rules frequently provide for a particular time limit for playing. Accordingly, it is an object of the present invention to provide an indication of a preset elapsed time, and to provide for the possible indication of time of day or elapsed time. U.S. Pat. Nos. 3,928,960 and 3,803,834, both to Reese, disclose conventional arithmetic calculators in combination with a time-of-day indication, but do not teach the application of game scoring in their respective calculator functions.
SUMMARY OF THE INVENTION
The present invention is applied to an electronic calculator for scoring of tennis and similar games in which winning of a game requires one opponent's score to be a specific number of points greater than the score of the other opponent. To avoid the use of point-counting registers of infinite or impractically large numeric capacity, the present invention allows either score to reach a maximum value, and thereafter operates to decrement the opponent's score until a condition is reached in which the winning of a new point results in the winning of a game. Means are provided to clear an incorrect entry and return to the previous, valid score values. For games in which the achievement of a particular set of point values changes the method of declaring scores, as for example the use of "deuce" or "advantage" scores in tennis, display means and display encoder circuitry are provided to recognize such an endgame condition and to display the scores as required.
Additional means are provided to count and display the number of games won for each opponent, to derive and display a court-change indication based on the number of games played, and to derive and indicate the passage of a particular time limit, as is often required when players are using shared facilities.
The present invention makes use of logic circuitry which may be packaged as medium--or large-scale integrated circuits, so that it may be small and light enough for the players to wear on a belt, or in a configuration similar to a wristwatch, or in combination with an electronic wristwatch with shared or separate displays and controls.
These and other features, objects and advantages of the present invention will become apparent to those skilled in the art from a consideration of the following detailed description of a preferred embodiment of the invention, taken in conjunction with the appended drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a drawing of a control and display panel for actuation of the present invention and for display of the results; and
FIG. 2 is a block diagram showing a preferred partitioning of circuit modules within the present invention; and
FIG. 3 is a logic diagram of data entry keys and associated circuitry of the preferred embodiment; and associated circuitry of the preferred embodiment; and
FIG. 4 is a block diagram of memory means for deriving and storing score results, and
FIG. 5 is a logic diagram of counter means for deriving and storing score results; and
FIG. 6 is a logic diagram for circuitry common to the scoring for two players for use with the counter means of FIG. 5; and
FIG. 7 is a logic diagram of a display decoder and game score display means of the present invention; and
FIG. 8 is a logic diagram of circuitry for calculating and displaying set score of the present invention; and
FIG. 9 is a logic diagram of circuits common to the set score calculation and display for two players.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, there is shown one of many possible layouts of a control and display panel for activating the present invention, and for viewing the results of its calculations. A switch 10 applies power from a suitable storage cell or similar power source. A CLEAR key 11 causes all scores to be effectively set to zero, and all internal status registers to be reset to an appropriate inital value. A pair of point-entry keys 12 causes the score of each of two players to be incremented, and a CLEAR ENTRY key 13 reverses the process in the event of an incorrect entry by the user.
Game displays 14 and 15 show the current value of each player's score in a format that is suitable for the game being played. So that the calculator may be capable of accumulating the number of individual games won by each player, there is included one set score display 16 for each player. The set display 16 may additionally be capable of blinking for a period of time after a new game has been won, as an auxiliary means for indicating which of the two players has won the most recently completed game. A court change indicator 17 may be included to indicate that the players must change courts, or perform another action which is based on alternate games completed. In tennis, the court change indicator is configured to light whenever the sum of the set scores is an odd number, i.e., after every other game. An additional indicator, not shown in FIG. 1, may be a COURT TIME ALARM, which may be a visible indicator or an audible alarm, and whose purpose is to remind the players that a specified period of time has passed since their period of play began. In tennis, for example, a one-hour time limit is typical for the use of shared courts.
As a means to facilitate the use and interpretation of results of scoring, both the data entry keys 12 and the score indicators 15 and 16 may be compatibly color coded so that the user has an immediate and clear idea of which keys to press and of which scores are associated with which keys.
Referring now to FIG. 2, there is shown the perferred embodiment of the present invention, in the form of a block diagram. It will be understood that lines representing signal flow between and among the different modules is for illustrative purposes, and that a wide variety of partitioning modes is possible, within the constraints of the matter disclosed herein. A KEY ENCODER AND STROBE GENERATOR 20 contains the function keys 11, 12 and 13 of FIG. 1, and additionally contains storage registers, logic and strobe-generation circuitry to provide appropriate command signals to the remainder of the circuits and displays. A GAME STATUS REGISTER AND LOGIC 21 contains registers and logic that are commonly required to calculate and display the game scores of both players. GAME SCORE REGISTERS AND LOGIC 22 are duplicated identically for each player and contain a counting register appropriate to the game being scored, in conjunction with logic to cause each player's score to be changed as each successive point is scored, or as a scored point is withdrawn via the CLEAR ENTRY key 13 of FIG. 1. Because it is advisable from the standpoint of keeping circuitry to a practical minimum, certain functions are created in one of the GAME SCORE REGISTERS AND LOGIC 22, and used as an input in the opponent's corresponding logic. Hence, the data flow is shown as running in both directions between the GAME STATUS REGISTER 21 and the GAME SCORE REGISTER 22. Based on the logical signals derived in 22 and elsewhere within the calculator, a GAME ENCODER AND DISPLAY 23 encodes the resulting score into display format for each player and presents it on a pair of conventional seven-segment display devices shown as 14 and 15 in FIG. 1.
The essential functions of both the game and set score calculating modules are twofold: to store a digital representation of the current score in each case, and to replace that score with a new one on command, based on a logical combination of the current score and the input keys being actuated. Because there are many conventions associated with logic design, and many design choices that may be passed on economy or availability of components but are otherwise arbitrary, it will be understood that a variety of different combinations of data registers and logic elements may be constructed without departing from the inventive concept disclosed herein.
Referring now to FIG. 3, there is shown preferred means for decoding keystrokes and generating strobe and control signals to actuate the remainder of the circuitry of the invention. The key switches 11, 12 and 13 are drawn as the electrical equivalent of those of FIG. 1, and in the preferred embodiment will create a low logic level whenever each key is depressed. It will be recalled that the actual polarities of these resultant logic signals, as well as all the remaining signals disclosed herein, are totally arbitrary and may be exchanged at will, provided that they remain logically compatible with the signals which will be used in combination with them.
Upon depression of the ENTER A switch 12a or the ENTER B switch 12b, a register 30, also known as a flip-flop or a bistable latch, will be set to a state corresponding to output signals POINT A or POINT B, respectively, as an indication of which player is to receive the new point. At approximately the same time, an OR gate 32 generates a pulse meaning that either one of the ENTER switches 12 has been depressed. This pulse sets another register 31, as an indication that the last action was a SCORE as opposed to a CLEAR ENTRY condition. If either a SCORE or a CLEAR ENTRY action has taken place, a monostable multivibrator or triggering device 35 generates a pulse called STROBE upon release of the key in question. To prevent multiple triggering of the CLEAR ENTRY function, it is desirable to provide an INHIBIT function to the triggering device 35, whose logic state is derived from the CLEAR ENTRY signal and the logical inverse of the SCORE signal, as combined in the AND gate 34.
It will be observed that all references to AND gates and OR gates will be construed to include corresponding inverted functions such as NAND and NOR, and that a small circle drawn at an input or output denotes a logic level inversion that is appropriate to the signals being acted upon within the preferred embodiment.
Finally, depression of the CLEAR key 11 will generate a pulse of appropriate level to reset registers within the invention at the start of operation. This function may be performed automatically when power is first applied, as is common and well known in the art. As is also common, it is desirable to provide "pull-up" resistors to each keyswitch to firmly establish its inactive electrical state and prevent false triggering due to electrical noise. Although not shown on the drawings, each active circuit requires the application of electrical power, and grounds for power and signal.
Recalling that two of the principal functions of the invention are to store each new score as it is calculated, and to derive the next score based on a logical combination of the previous score and the keyswitch last actuated, FIG. 4 illustrates one method for accomplishing these objectives. A data register or LATCH 41 is used to contain a representation of the last score derived.
In the preferred embodiment, as applied to the game of tennis, the scores of two players are contained in two two-bit registers (A0, A1) and (B0, B1), where A and B refer to the respective players and the digits 0 and 1 refer to the lower-order and high-order binary digits respectively. The meaning of the digits with respect to ordinary scoring is simply a binary count of the points received; thus in tennis, register (A0, A1) would initially contain score representations according to the following table:
______________________________________ TENNIS SCORE A1 A0______________________________________ 0 (LOVE) 0 0 15 0 1 30 1 0 40 1 1______________________________________
In tennis and many other sports, however, there is a condition within a game where the numerical scoring as illustrated above is abandoned, and the scorekeepers switch to an alternate method based on points-ahead rather than the absolute number of points scored. The convention in tennis, for example, is to declare the score DEUCE or DEUCE GAME whenever the score is 40--40, and every time thereafter that the players have an identical number of points. When one player has a one-point lead, the score is declared ADVANTAGE or AD for that player, and a two-point lead constitutes the winning of GAME.
To account for such a condition within the present invention, a single register has been provided within the LATCH 41 of FIG. 4, and its output state is called END. Thus for a complete game of tennis, all the scores possible may be represented by the following table:
______________________________________TENNISSCORE A1 A0 END______________________________________0(LOVE) 0 0 015 0 1 030 1 0 040(not DEUCE) 1 1 0DEUCE 1 1 1AD (player A) 1 1 1AD (player B) 1 0 1______________________________________
All that is required to calculate a subsequent score is to decode the combined logic states of the registers within the LATCH 41, comprising A0, A1, B0 and B1, in combination with the input logic states POINT A (which is always the logical inverse of POINT B) and whether or not the SCORE condition (as opposed to the CLEAR ENTRY condition) is being requested by the circuitry of FIG. 3. One method of accomplishing the decoding function is via the use of a NON-VOLATILE MEMORY 40, which may be any of a wide variety of memory products including a read-only memory or any form of magnetic core provided with non-destructive readout or a means for refreshing its contents after reading. The address of a particular memory location comprises the logic states of A0, A1, B0, B1, POINT A and SCORE presented in any order, and the contents of the memory location will be preset with the appropriate values of A0, A1, B0 and B1. The actual contents of such a memory table are not presented here because of their length, although one skilled in the art could easily construct such a table and pre-program the NON-VOLATILE MEMORY 40 to select new values for each score condition.
Because of its utility in interpreting the resulting scores for display purposes, an additional output function END is shown in FIG. 4. It is not absolutely necessary to include this function, although it is preferable to render the required logic circuitry minimum that it be included in the outputs presented to LATCH 41. By reference to the latter of the two score tables above, it is observed that a DEUCE is represented by a TRUE bit in both registers A0 and A1. The same condition could just as effectively be represented by a TRUE in the A1 register and a FALSE in the A0 register for DEUCE, provided that A registers and the B registers both contained the same score, and means were provided to inform the display circuitry that the score being represented were a DEUCE as opposed to 30-30 or 40-40. The END logic state serves this function for use in display coding, and in the preferred embodiment it is also used to force the internal representation of a DEUCE score to 11 (binary) rather than 10, for purposes of reducing logic required to decode the score. Thus the END option is included as a latched output in FIG. 4.
Still with reference to FIG. 4, the STROBE input generated within the circuitry of FIG. 3 or its functional equivalent is used to cause the MEMORY 40 to retrieve each new score, and the LATCH 41 to preserve the retrieved output. It will be understood that memory products with built-in latches for output are functionally and structurally equivalent to the combination of FIG. 4.
Another embodiment of the score register and score encoder combination of the present invention is disclosed in FIGS. 5 and 6. Referring now to FIG. 5, a pair of registers 50 and 51 are shown as containing the score bits A1 and A0, respectively, it being understood that the entirety of the circuit in FIG. 15 is replicated for players A and B, identically. In the circuit of FIG. 5, the registers themseleves contain decoding inputs J and K and are commonly known as J-K flip-flops. Whenever a strobe is applied to the clocking input C of either, the resulting output state will transition to a new value depending upon the initial states of J and K, according to the following table:
______________________________________INITIAL VALUES OUTPUT J K Q______________________________________0 0 Same as prior output0 1 01 0 11 1 Opposite prior output______________________________________
It will be shown that the circuit of FIG. 5 can be made to function as an up-down counter which may be loaded to an initial state 01 (binary) or 00, to satisfy the scorekeeping requirements of the present invention. Whenever the STROBE is received, the AND gate 57 will allow that strobe to pass to registers 50 and 51 if the output of the EXCLUSIVE-OR gate 56 is high. The latter condition will be true whenever the POINT A input is TRUE, unless the EXCHANGE STROBES input is TRUE, in which case the gate 57 will pass the strobe only if POINT B (the inverse of POINT A) is in the TRUE state. As an example of the need to exchange the strobes in this fashion, it will be recalled that following a DEUCE score, it is desirable upon the winning of a point by player B to decrease player A's score register to binary 10 rather than increment player B's register, which would be interpreted by the display and set-score circuitry to denote the winning of a game. Whenever registers 50 and 51 receive a strobe from gate 57, they will assume a new state based on their respective J and K inputs. Referring to the truth table shown above, the registers 50 and 51 will increment their binary count under normal circumstances. With J0 and K0 both TRUE, the lower-order bit A0 will always change states, as it should for either an up--or down-count. If the special-condition inputs DOWN and FIRST are both in the FALSE state as they will be for usual operation, the value of J1 and K1 will both assume the value of A0 after their passage through gates 52, 53 and 54. This will mean that when the prior state of A0 is TRUE, A1 will change states, and when the prior state of A0 is FALSE, then A1 will not change states. Thus the binary up-count 00, 01, 10, 11, 00 . . . etc. is satisfied and the circuit functions as an up-counter.
By presentation of the DOWN input signal, the sense of A0 is inverted as it passes through the EXCLUSIVE-OR gate 52, the binary sequence 11, 10, 01, 00, 11 . . . is satisfied and the circuit functions as a down-counter.
Under special circumstances, the register comprising 50 and 51 will need to be loaded to an initial value. After a game has been won by one of the players, and when the next point has been scored, it is desirable to set the score of the winner of that point to binary 01, and that of the loser to binary 00. To accomplish this, the higher-order bits A1 and B1 are both set to zero by loading the J1 and K1 inputs of each register with 0 and 1 respectively. Existence of a TRUE state on input FIRST will force J1 to FALSE via the AND gate 53, and will force K1 to TRUE via the OR gate 54. To load the proper initial score into the lower-order bit of each register, the winner's J0 input will be FALSE due to AND gate 55 in the opponent's register. Consequently, the J-K inputs represented by binary 10 will render the winner's low-order register 1, and, by symmetry, the loser's corresponding register 0.
Although the embodiment shown uses J-K flip-flops as the register and counting element, those skilled in the art will observe that there are other choices of register element. For example, a device commonly known as a D flip-flop will assume its input state upon receipt of a strobe, and it is easy for those skilled in the art to configure that logic gates to derive an appropriate D input rather than two J-K inputs for each one-bit register.
In addition to the score-calculating functions, certain outputs of each individual rgeister are useful for display and other functions to be described below. Thus the AND gate 58 goes TRUE whenever both bits of the register are 0, and the AND gate 59 whenever they are both 1, creating outputs A00 and A11, respectively. The AND combination of A11 and POINT A is derived by gate 60 for use in detecting the winning of a new game.
Referring now to FIG. 6, there is shown a circuit for providing the common logic signals that are used by both the individual score registers 22a and 22b of FIG. 2. The AND combination of A11 and B11 creates a DEUCE condition via gate 67, whose output is used to preset register 65 and render the END signal TRUE. The latter signal is needed for the display to distinguish between numerical scores 0-15-30-40, and the endgame scores DEUCE and AD. The same register 65 is cleared during a STROBE cycle by setting its J input to FALSE and permanently wiring its K input to TRUE. The J-K combination represented by binary 01 then forces the END output to FALSE.
Similarly, to create the logic state NEW, which records the fact that a game has been completed and is awaiting a new point or a CLEAR ENTRY command, the register 66 has its J input set to TRUE by either (A11 AND A) or (B11 AND B) via the OR gate 69. The K input of the same register 66 is set to FALSE normally, but goes TRUE when its own output is TRUE, and is thus self-clearing. The possible state changes are thus TRUE (JK=10) and FALSE (JK=01). Under normal operation, JK=00, and no change takes place, i.e., the NEW output remains FALSE. The remaining input condition, JK=11, will reset the NEW state to FALSE just as JK=01. A system CLEAR will preset the NEW register 66 to TRUE and blank the displays.
As with the individual registers, certain auxiliary logic signals are useful. SCORE•DEUCE will set the EXCHANGE output to TRUE and hence the DOWN output to TRUE unless the SCORE input is FALSE, via the action of AND gate 70 and EXCLUSIVE-OR gate 74. The same effect is derived via AND gate 71 by the values END•SCORE•GAME. The latter value is derived in OR gate 73. The combination NEW•SCORE creates the logic state FIRST, to signify the beginning of a new game. Finally, DEUCE+NEW is derived in OR gate 75 and inhibits display of the left digit of the score in ENABLE L.
Referring now to FIG. 7, there is shown a circuit for decoding the game registers 50 and 51 of FIG. 5 and the auxiliary registers 65 and 66 of FIG. 6, plus their logical combinations and keyboard input signals, into a format suitable for display in a commonly available device such as a light-emitting diode (LED) or liquid crystal display (LCD) with seven segments. One of the principal features of the present invention is the encoding of a display of two or more digits using common circuitry, and the ability efficiently to create symbols for the DEUCE and ADVANTAGE conditions.
In FIG. 7, conventional symbology has been used for the seven segment displays 14a and 15a, namely that lower-case letters a through g denote the seven segments individually as shown on reference FIG. 15a. The action of the decoder, as embodied in gates 80 through 90, is best understood by reference to the following logic table:
______________________________________DIGIT SEGMENT CONDITION______________________________________LEFT a = ##STR1## b = TRUE (always active) c = TRUE d = ##STR2## e = END f = -d · g g = ##STR3##RIGHT a = e (LEFT) b = g (LEFT) c = TRUE d = TRUE e = b f = a g = -e + END______________________________________
It will be understood that a TRUE condition on one of the display segments will cause the segment to become active, and will either illuminate or present a contrasting reflection, depending upon its construction. It is desirable to blank one or both the digits under some circumstances; each digit will become active for the following input conditions:
LEFT: [ENABLE L•A0]+]ENABLE L•A1•A0 •END]
RIGHT: NEW+[DISPLAY B0•END].
It will also be understood that the display circuitry is symmetrical for two players A and B, including the creation of DISPLAY A0 and DISPLAY B0 signals to be routed to the opponent's display encoder.
The resulting encoded signals are shown to the right of FIG. 7, including the all-blank condition (new game or opponent's advantage), the scores 0, 15, 30 and 40, and the derived alphabetic scores Ad and d, the latter being logically identical to Ad but with the left digit blanked. It will be observed that due to equalities within the logic table, only seven active lines are required for output; this means that an encoder similar in construction to a conventional seven-segment numeric display encoder could be built or created from a programmable logic array (PLA).
Referring now to FIG. 8, there is shown a preferred circuit for counting and displaying set scores, or the tally of games won. An up-down counter 103 is driven by the STROBE accompanying the player's own game score, and under normal operation will increment the set score whenever a new game is won, as identified by the logical input SET UP, to be described below. If a new game is followed by a CLEAR ENTRY, however, it is necessary to count down, and the combination of POINT A•SET DN accomplishes this via the AND gate 102. Counter 103 is in this preferred example a four-bit binary-coded decimal counter whose outputs SET A0 through SET A3 drive a BCD to seven-segment display encoder 104, such as is common in the art. The encoder 104 in turn drives a seven-segment numerical display device 16a, which creates the digits 0 through 9. A separate BLINK input causes the selected display to flash for a predetermined time interval after the winning game. The set score calculator and display of FIG. 8 is duplicated identically for players A and B, except for the naming of logic signals.
Referring now to FIG. 9, there are shown preferred circuits for commonly creating the logic signals necessary to drive the individual set score registers. The logical ouput SET UP used in FIG. 8 is created by the AND gate 110 using SCORE and GAME as its inputs. Similarly, NOT SCORE and NEW are combined in AND gate 111 to create the output SET DN.
EXCLUSIVE-OR gate 112 determines that the gross set scores are odd or even as represented by their low-order bits SET A0 and SET B0, and activates a COURT CHANGE INDICATOR 17, shown here as a LED indicator.
Monostable timers 114, 116 and 117 act to flash the winner's set score display upon receipt of a trigger BLINK A or BLINK B from the individual set score registers. Timer 114, driven by OR gate 113, will start the flashing and keep it active for a period of time (approximately two seconds is preferred), and the timers 116 and 117 alternately turn the display on and off, via the output called BLINK, which is combined with the most recent point signal (POINT A of FIG. 8) to flash the appropriate display. Finally, timer 118 as set to start timing when power is applied to the entire device, and to activate a visual or aural alarm 119 after a preset time limit. For tennis, a one-hour time limit is frequently applied to the use of shared courts, and is preferred for the present embodiment. While a specific embodiment of the invention has been described, it will be realized by those skilled in the art that various changes may be made therein without departing from the spirit or intent of the inventive concept. Therefore, it is intended that the scope of the present invention be delimited only by the claims appended below. | An electronic device for calculating, storing and indicating the scores and related information for a game of tennis is described. The circuit provides for the special requirements of tennis and similar games by recognizing the existence of an endgame condition such as "deuce" in tennis and registering each new score as a function of the previous score and the point most recently won. Both up-down counters and decoders using non-volatile memory, including "read-only memory" (ROM) are disclosed for the point-calculation function, and a display encoder is described which efficiently provides for the display of alphanumeric scores, including "deuce" and "advantage" conditions. The invention includes features for indicating court change requirements, elapsed time, time of day, and display emphasis when a game is won. All score calculations are subject to a clear-entry feature to rectify operating error. | 31,786 |
RELATED PATENT DATA
[0001] This application claims priority to U.S. Provisional Patent Application Ser. No. 61/946,610, filed Feb. 28, 2014, entitled, “System and Method for Time Managing Loads in the Transport of Goods”, the entirety of which is hereby incorporated by reference.
TECHNICAL FIELD
[0002] This disclosure pertains to business-to-business (B2B) transactions. More particularly, this disclosure relates to apparatus and methods for managing the transportation of freight.
BACKGROUND
[0003] Techniques are known for scheduling loads for delivery on behalf of a customer using a carrier. Such scheduling typically involves collating of multiple independent communications from one or more of phone calls, emails, and facsimiles from one or more customer and/or carriers. Logistics capabilities have yet to minimize efforts in intermediating load delivery for customers by carriers. Therefore, there exists a need to improve temporal selection of a load to be delivered and a load to be scheduled for delivery by a carrier that is to be transported for a prospective transportation industry customer.
SUMMARY OF THE INVENTION
[0004] A system and method are provided for managing the transportation of freight between shippers, brokers, and carriers. Functional interaction between the shippers, brokers, and carriers is provided in a different manner than is currently implemented in a “bricks & mortar” business model.
[0005] According to one aspect, a computer-implemented system of providing date and time selection to a client from a server is provided to enable temporal scheduling of a load to be transported for a prospective transportation industry customer. The system includes user information and instructions and a computer processor. The user information and instructions are stored in a computer memory at a host server. The computer processor accesses the memory at a host server to retrieve the user information and instructions and executes the instructions to perform steps including: presenting from the server to the client at a user interface one or more of a selectable date range and a time range for which the user provides a temporal-based requirement for picking up a customer load; enabling selection of one or more of a date range and a time range at a user interface of the client; receiving a selected one or more of the date range and the time range at the server from a user at the client; storing the received information into the database; associating the stored temporal data with a waypoint indicative of a cargo delivery destination desired by a customer; associating the stored waypoint to a load; and associating the attached load to the customer.
[0006] According to another aspect, a method is provided for enabling date and time selection from a client through a server to enable temporal scheduling of a load to be transported for a prospective transportation industry customer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Preferred embodiments of the disclosure are described below with reference to the following accompanying drawings.
[0008] FIG. 1 is a block diagram of the central processing system and network used to carry out temporal selection of a load to be delivered and a load to be scheduled for delivery by a carrier that is to be transported for a prospective transportation industry customer according to an exemplary embodiment.
[0009] FIG. 2 illustrates a flowchart for implementing user authentication and permissions to access through one or more interfaces the features and functionality of FIG. 1 in accordance with an exemplary embodiment.
[0010] FIG. 3 illustrates a flowchart for displaying load data to users and clients and for selecting and transmitting temporal data requirements for shipping the load.
[0011] FIGS. 4A and 4B together illustrate a flowchart for a customer selecting carrier bids, approving carrier rates, accepting carrier bids, and storing multiple customer approved bids on a load.
[0012] FIG. 5 illustrates a screen shot of a web page for a simple request for a broker for posting loads and identifying shippers and receivers of a type that would be displayed on the screen of one of the computers connected for communication with the processing circuitry of the server for the system of FIG. 1 .
[0013] FIG. 6 illustrates a screen shot of a web page for a date/time/selection menu that pops up when a user selects a “Date & Time” field in one of the shipper and received fields of FIG. 5 .
[0014] FIG. 7 illustrates a screen shot of a web page showing a user “mousing over” a selected date range field prior to selecting a time range.
[0015] FIG. 8 illustrates a screen shot of a web page showing a selected temporal range achieved in FIG. 7 .
[0016] FIG. 9 illustrates a screen shot of a web page showing selection of a receiver “Set Date & Time” field.
[0017] FIG. 10 illustrates a screen shot of a web page showing a selected a temporal range for the pop-up menu of FIG. 6 .
[0018] FIG. 11 illustrates a screen shot of a web page for realizing the temporal range selected in FIG. 10 .
[0019] FIG. 12 illustrates a screen shot of a user login page.
[0020] FIG. 13 illustrates a screen shot of a customer dashboard.
[0021] FIG. 14 illustrates a screen shot showing customer load details.
[0022] FIG. 15 illustrates a screen shot showing a customer new load.
[0023] FIG. 16 illustrates load details including a new load with a temporal range selection.
[0024] FIG. 17 illustrates a flowchart depicting account manager load interaction flow and privileges in accordance with an exemplary embodiment.
[0025] FIGS. 18A and 18B together illustrate a flowchart depicting a system for rating carriers having checks and balances in accordance with an exemplary embodiment.
[0026] FIGS. 19A and 19B together illustrate a flowchart depicting logic behind selection of a temporal range in accordance with an exemplary embodiment.
[0027] FIG. 20 illustrates a screen shot for a carrier profile to access through one or more interfaces the features and functionality of FIG. 1 in accordance with an exemplary embodiment.
[0028] FIG. 21 illustrates a screen shot depicting a load profile with quotes attached to a load with ratings.
[0029] FIG. 22 illustrates a screen shot depicting a menu for interacting with a carrier rate on a load menu.
[0030] FIG. 23 illustrates a screen shot depicting a customer profile.
[0031] FIG. 24 illustrates a screen shot depicting a brand new load.
[0032] FIG. 25 illustrates a screen shot depicting the selection of equipment for the new load depicted in FIG. 24 .
[0033] FIG. 26 illustrates a screen shot depicting a new load and adding a line item to a customer's invoice.
[0034] FIG. 27 illustrates a screen shot depicting realization of the line item added to the customer's invoice of FIG. 26 .
[0035] FIG. 28 illustrates a screen shot depicting the ability to add a shipper and a receiver for a designated city and state.
[0036] FIG. 29 illustrates a screen shot depicting a pop-up menu while selecting a temporal date range.
[0037] FIG. 30 illustrates a screen shot depicting the pop-up menu of FIG. 30 while selecting a temporal time range.
[0038] FIG. 31 illustrates a screen shot depicting the pop-up menu of FIGS. 30 and 31 while selecting a temporal “after” time range.
[0039] FIG. 32 illustrates a screen shot depicting a realized selected temporal range implemented via actions depicted in FIGS. 29-31 .
[0040] FIG. 33 illustrates a screen shot depicting automatically converted units of weight for a specific cargo over that entered in the screen shot of FIG. 32 .
[0041] FIG. 34 illustrates a screen shot depicting a load status change “PUT ON HOLD” resulting from selection of a “POST TO LOAD BOARDS” field in FIG. 35 .
[0042] FIG. 35 illustrates a screen shot depicting the adding of a carrier quote where permissions change the rate and “XYZ TRUCKING” is added.
[0043] FIG. 36 illustrates a screen shot depicting the addition of a second carrier quote to provide for multiple quotes.
[0044] FIG. 37 illustrates a screen shot depicting a carrier quote menu.
[0045] FIG. 38 illustrates a screen shot depicting a pop-up menu for adding carrier quote equipment.
[0046] FIG. 39 illustrates a screen shot depicting realized changes of carrier quote equipment type from FIG. 38 to FIG. 39 .
[0047] FIG. 40 illustrates a screen shot depicting the addition of a note to a carrier.
[0048] FIG. 41 illustrates a screen shot depicting realization of the added note input in FIG. 40 .
[0049] FIG. 42 illustrates a screen shot depicting realizing equipment changes for the listed carrier with the added note and approval of “XYZ TRUCKING”.
[0050] FIG. 43 illustrates a screen shot depicting realized changes for approved carrier “XYZ TRUCKING”.
[0051] FIG. 44 illustrates a screen shot depicting creation of carrier rate paperwork.
[0052] FIG. 45 illustrates a screen shot depicting a pop-up screen that provides a secondary check to a user indicating that this operation is desired by the user.
[0053] FIG. 46 illustrates a screen shot depicting realization of carrier rate confirmation paperwork.
[0054] FIG. 47 illustrates a screen shot depicting realization of customer rate confirmation paperwork.
[0055] FIG. 48 illustrates a screen shot depicting selection of change of load status to “IN TRANSIT”.
[0056] FIG. 49 illustrates a screen shot depicting realization of selection of the changed load status in FIG. 48 .
[0057] FIG. 50 illustrates a screen shot depicting added notes to a load with carrier permissions to view.
[0058] FIG. 51 illustrates a screen shot depicting that selection is being made for making it visible to a customer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0059] This disclosure is submitted in furtherance of the constitutional purposes of the U.S. Patent Laws “to promote the progress of science and useful arts” (Article 1, Section 8).
[0060] FIG. 1 shows a platform or system 10 used to carry out temporal selection of a load to be delivered and a load to be scheduled for delivery by a carrier that is to be transported for a prospective transportation industry customer according to an exemplary embodiment. The system 10 includes a network, such as the Internet 12 , a server 14 , and terminals, or clients 16 , 18 , 20 , 22 , 24 and 26 . Server 14 includes one or more processor having processing circuitry 28 and data storage having memory 32 communicating with the processing circuitry. Memory 32 includes, or defines one or more databases 33 configurable to store data. Server 14 includes one or more network adapters 15 that enables communication with a network, such as the Internet 12 . Clients 16 and 18 comprise shipper terminals used by Shipper A and Shipper B, respectively. Clients 20 and 22 comprise broker terminals used by Broker A and Broker B, respectively. Clients 24 and 26 comprise carrier terminals used by Carrier A and Carrier B, respectively. Each client is further understood to include a wired or wireless communications device, memory, one or more processors having processing circuitry, an input/output device with a display driver for connecting the client to an input/output (I/O) device, such as a display, a keyboard, and a mouse. The display driver transforms digital data into visual images perceptible by a user at the client capable of generating screen images visible on the display. In several forms, client is a personal computer, a laptop, a tablet, or a smart phone.
[0061] As shown in FIG. 1 , it is understood that one or more input modules can be generated by server 14 . Such modules are each configured to cause a graphical user interface to be rendered on a user's client machine, or computer to enable a user to input data relating to selection, scheduling, and delivery of a load (freight). Such interface renders features provided on the screen shots provided herein. Similarly, output modules are configured to display results of the data that is input by a user.
[0062] FIG. 2 illustrates a flowchart for implementing user authentication and permissions to access through one or more interfaces the features and functionality of FIG. 1 in accordance with an exemplary embodiment. With reference to FIG. 2 , a flow of logic that is executed in various embodiments, when implementing user authentication and permissions is illustrated. The process can start at step 200 . After start 200 , the process proceeds to step 201 where a user public page is presented at one or more clients where a user can input their credentials. After step 201 , the process proceeds to step 202 where the input user credentials are sent via HyperText Transfer Protocol Secure (HTTPS) to server 14 (of FIG. 1 ). After performing step 202 , the process proceeds to step 203 where a user is authenticated (with a userid and a password). If the user is authenticated, then the process proceeds to step 204 . If the user is not authenticated, the process proceeds to step 201 . In step 204 , the process compares user type and user group to determine which category a user is identified with including a customer interface at step 205 , a carrier interface at step 206 and a “Type N” interface at step 207 . Once a user has been identified and assigned to a user category, the process proceeds to step 208 . In step 208 , the process prepares permissions and views based on a user sub-type, such as “broker”, “customer”, and “account manager”. After performing step 208 , the process proceeds to step 209 . In step 209 , a completely functional interface is displayed to the authenticated (identified) and permissioned user.
[0063] FIG. 3 illustrates a flowchart for displaying load data to users and clients and for selecting and transmitting temporal data requirements for shipping the load. With reference to FIG. 3 , a flow of logic that is executed in various embodiments, when implementing the display of load data to users and clients and for selecting and transmitting temporal data requirements (date range and time range) is illustrated. The process can start at step 300 . In step 300 , a complete interface (with complete interface functionality) is displayed to a user at a specific client. After performing step 300 , the process proceeds to either step 301 or step 302 . In step 301 , a user searches for a load, then proceeds to step 302 . In step 302 , a user selects a load default from a list. After performing step 302 , the process proceeds to step 303 where a client sends a request to server 14 (of FIG. 1 ). After performing step 303 , the process proceeds to step 304 where the server returns load information to the client. After performing step 304 , the process proceeds to step 305 where the client displays the load data. After performing step 305 , the process proceeds to step 306 where the user selects a waypoint temporal data input field (such as a range of dates and/or a range of times) for which a designated load is to be picked-up/delivered to a desired destination. After performing step 306 , the process proceeds to step 307 where the client displays a user interface with a temporal data selector (a date range and/or a time range). After performing step 308 , the process proceeds to step 308 where the user inputs required temporal data (date range and/or time range). After performing step 308 , the process proceeds to step 309 where the client transmits the selected temporal data to the server 14 (of FIG. 1 ). After performing step 309 , the process proceeds to step 310 where the server stores the selected temporal data to an associated waypoint (a coordinate or location on the freight delivery path).
[0064] As detailed in FIG. 3 , temporal date/time range storage is provided for logistics purposes. For each “waypoint” in a freight delivery (begin, midpoint, end, etc.) on a load to be transported, there exist pick-up and drop-off dates and/or times. There exist five different options to fill the temporal field with data including: “Between”; “Before”; “After”; “At”; and “N/A” (not available). These dates and times are then parsed in different ways in order to distribute them to industry standard load boards, such as GetLoaded, Dat360, and Internet Truckstop. Such distribution is an optional feature.
[0065] As used herein, the terms “carrier rate”, “carrier bid”, and “carrier quote” are used interchangeably until a carrier is fully signed on for a load, after which the designation becomes “carrier-on-board”.
[0066] FIGS. 4A and 4B together illustrate a flowchart for a customer selecting carrier bids, approving carrier rates, accepting carrier bids, and storing multiple customer approved bids on a load. With reference to FIGS. 4A and 4B , a flow of logic that is executed in various embodiments, when implementing the display of load data to users and clients and for selecting and transmitting temporal data requirements (date range and time range) is illustrated. The process can start at step 400 . After step 400 , the process proceeds either to step 401 or step 402 . In step 401 , a customer searches for a load using a specific client. After performing step 401 , the process proceeds to step 402 where a user selects a load default from a list of loads. After performing step 402 , the process proceeds to step 403 where the client sends a request to the server 14 (of FIG. 1 ). After step 403 , the process proceeds to step 404 where the server returns load information to the client. After step 404 , the process proceeds to step 405 where the clients displays load data. After step 405 , a query is made at step 406 as to whether a specific account type and load status is enabled to view bids. If not, the process proceeds to step 407 where a load is displayed without any bids. If enabled, the process proceeds to step 408 where all current carrier bids and/or quotes are displayed at a client (including multiple bids displayed concurrently). After performing step 408 , the process proceeds to step 409 where a customer selects a carrier bid from a list of currently submitted bids. After performing step 409 , the process proceeds to step 410 where a multi-variate query is made about four responses that can be taken after carrier bid information is displayed at a client. At step 410 , a user is presented with four choices. A first choice is triggered by a user selecting an approved button (on a user interface of the client) that causes the process to proceed to step 411 . A second choice is triggered by a user selecting a decline button (on a user interface of the client) that causes the process to proceed to step 422 . A third choice is triggered by a user selecting an add note/comment via a text box and submitting it that causes the process to proceed to step 423 . A fourth choice is triggered by a user selecting a click on name button (listing a static profile for a carrier) which proceeds to step 424 . After performing step 424 , the user then clicks on a back button to return the process back to step 410 . In step 411 , the customer approves the provided carrier rate. In step 422 , a customer denies a carrier rate and the process proceeds to step 414 . After a customer denies a rate at step 422 , the system changes the status of the bid relative to the customer's interface. In step 423 , a customer sends the carrier a message and the process proceeds to step 414 . After step 411 , the process proceeds to step 412 where the client sends approval to the server. After step 412 , the process proceeds to step 413 where the server marks the bid as approved. After step 414 , the process proceeds to step 414 where a notification is dispatched to the carrier and/or account representative. After step 414 , the process either proceeds back to step 409 or forward to step 415 . In step 415 , the server stores multiple customer approved bids on a load. After step 415 , the process proceeds to step 416 where individual carriers are notified of bid approval and asked to confirm their availability to deliver a specific load. After performing step 416 , the process proceeds to step 417 where the carrier responds by confirming their availability (to the server). After step 417 , the process proceeds to step 418 where the server sets the first carrier to respond to the load. After step 418 , the process proceeds to step 419 where the server updates the load past the bidding status. After step 419 , the process proceeds to step 420 where the server sends out notification to all non-conforming carriers that the specific load is closed (and not open for bid acceptance). More particularly, the term “closed” is applied to loads to denote that the load is delivered. After performing step 420 , the process proceeds to step 421 where the server sends out notification to the customer that a carrier has been set (or assigned) to carry their particularly load. At this point, the process terminates.
[0067] As detailed in FIG. 4 , a multiple quote and simultaneous approval process is disclosed. When a customer is logged in and look at quotes that have been submitted by various carriers, they are enabled with the ability to approve multiple carriers at the same time. Once this happens, an automated notification goes out to all carriers approved, requesting confirmation of their availability. The first carrier that logs into the website and provides an availability verification to complete the load in question is then changed to become the provider. The remaining carriers are then automatically notified that they were too slow to become the provider, and the load is no longer available.
[0068] FIG. 5 illustrates a screen shot of a web page for a simple request for a broker for posting loads and identifying shippers and receivers of a type that would be displayed on the screen of one of the computers connected for communication with the processing circuitry of the server for the system of FIG. 1 . More particularly, a cursor 501 is positioned over “Set Date & Time” field 502 which provides a selectable navigation link that opens up a temporal range pop-up window 601 depicted in FIG. 6 , below.
[0069] FIG. 6 illustrates a screen shot of a web page for a date/time/selection menu that pops up when a user selects a “Set Date & Time” field 502 in one of the shipper and received fields of FIG. 5 . More particularly, pop-up menu 601 includes a temporal date range selection menu item 602 and a corresponding temporal time range selection menu 603 via which a user can select a temporal range (time and/or date) using a single click/drag of a mouse and cursor over the calendar displayed in selection menu 602 . A temporal date range is shown as selection field 606 . A selectable date identifier “At” 607 is selected in menu 601 corresponding with a single selected date shown in a date field 605 shown directly below. Another date indicated by menu item 604 representing Jan. 22, 2104 shows the current date via a round circle, whereas the “At” selected date will show up on the calendar via a rectangular surround feature corresponding with the date shown in date field 605 . Other date identifiers of menu 601 for selecting a date, or date range that are selectable include, “Between”, “Before”, “After”, and “Don't Set”.
[0070] FIG. 7 illustrates a screen shot of a web page showing a user “mousing-over” and selecting date range field 606 (with a cursor) of temporal date range selection menu 602 separate from selecting a time range 609 via a “between” time field selection 608 of a temporal date range selection menu 602 . Furthermore, a temporal time range selection menu 603 is also provided for selecting and inputting dates for respective date ranges.
[0071] FIG. 8 illustrates a screen shot of a web page showing a selected temporal range achieved in FIG. 7 . More particularly, a cursor 801 is positioned over a selectable navigation date range link 802 that opens up the temporal range pop-up window 601 depicted in FIG. 7 , above.
[0072] FIG. 9 illustrates a screen shot of a web page showing selection of a receiver “Set Date & Time” field 902 by “mousing-over” a cursor 902 and selecting field 902 . More particularly, cursor p 01 is positioned over “Set Date & Time” 902 which provides a selectable navigation link that opens up a temporal range pop-up window 601 depicted in FIG. 10 , below.
[0073] FIG. 10 illustrates a screen shot of a web page showing a selected temporal range for the pop-up menu of FIG. 6 that pops up when a user selects a “Set Date & Time” field 902 in the receiver field of FIG. 9 . More particularly, pop-up menu 601 includes a temporal date range selection menu item 602 and a corresponding temporal time range selection menu 603 via which a user can select a temporal range (time and/or date) using a single click/drag of a mouse and cursor over the calendar displayed in selection menu 602 . A temporal date range is shown by selection field 1006 . A date identifier “Between” 1008 is selected in menu 601 corresponding with a range of dates shown in a date field 1005 shown directly below. Another date indicated representing Jan. 22, 2104 shows the current date via a round circle. Other date identifiers of menu 601 for selecting a date, or date range that are selectable include, “At”, “Before”, “After”, and “Don't Set”.
[0074] FIG. 11 illustrates a screen shot of a web page for realizing the temporal range selected in FIG. 10 . More particularly, a temporal date and time range 1102 and 1104 is provided for the shipper and the receiver, respectively.
[0075] FIG. 12 illustrates a screen shot of a user login page having a login menu 1201 for receiving user login information including email adrees, and password information that enables permissioned login to features of the website portal described variously in FIGS. 1-52 .
[0076] FIG. 13 illustrates a screen shot of a customer dashboard illustrating a customer's specific freight requests, or loads that a particular customer has pending. Loads are shown in various stages in any scenario. One exemplary shown freight request for shipping a freight load from Seattle, Wash. to Key West, Fla. is shown in field 1302 when a “My Freight” menu item 1304 is selected with a mouse (or input device) via cursor 1301 . A draft load request 1306 is shown for a load that the customer is still working on, but is not yet fully filled in and submitted. In contrast, field 1302 shows a customer name 1312 , an in-house tracking number 1318 for identifying a load, an originating location identifier 1314 with a preferred date of pickup identifier 1316 , and a destination location identifier 1320 with a preferred date of drop-off identifier 1322 . Furthermore, field 1302 includes a truck icon 1308 that traverses along a line 1310 from start location identifier 1314 at one end to finish location identifier 1320 at an opposite end. Position of truck icon 1308 is provide along line 1310 at a location corresponding with the distance presently travelled by the carrier with the cargo, as determined by GPS monitoring of the actual carrier (and cargo). In this way, a user of the system can monitor status (relative position) of the cargo and carrier relative to the total distance being traveled between the start location and the finish location during the delivery.
[0077] FIG. 14 illustrates a screen shot showing customer load details in a detail menu 1402 including status of a load submitted and pending, as well as status of carrier approval. A status indicator field 1404 shows the status of a shipping request under review.
[0078] FIG. 15 illustrates a screen shot showing a customer new load data entry input menu 1506 obtained by selecting a “Create New Load” identifier 1504 with a mouse cursor 1502 . Menu 1506 includes an explanation, or “How it works” explanation field 1508 , a “What are you shipping and where is it going?” field 1510 , a “Weight & Dimensions” field 1512 , and a “Shipping & Receiving Dates” field 1514 .
[0079] FIG. 16 illustrates load details including a newly created load realized by accessing “Create New Load” field 1504 with a temporal range pop-up menu 1603 . Menu 1603 is generated by selecting “Preferred Earliest Pickup Date” field 1602 within field 1514 using a mouse cursor 1601 .
[0080] FIG. 17 illustrates a flowchart for depicting account manager load interaction flow and privileges in accordance with an exemplary embodiment. With reference to FIG. 17 , a flow of logic that is executed in various embodiments, when implementing the creation and submission of load data is illustrated. The process can start at step 1700 . After step 1700 , the process proceeds to step 1701 where a load is created by a user. After performing step 1701 , the process proceeds to step 1702 where a query is made as to whether the created load has required data (for submission to the load boards). If so, the process proceeds to step 1704 . If not, the process proceeds to step 1703 . After step 1703 , the process terminates. In step 1703 , the load does not have required data and cannot be posted to the board(s). In step 1705 , the load board hooks are fired. After step 1706 , carriers add bids to the load on the load board. After performing step 1706 , the process proceeds to step 1707 where a broker approves a carrier (from those that have added a bid to the load). After performing step 1707 , the process proceeds to step 1708 where the load status changes to “waiting for pickup”. After performing step 1708 , the process proceeds to step 1709 where “waiting for pickup” hooks are fired that trigger a series of system events that are mandatory for that status of the load and operation of the system. After performing step 1709 , the process proceeds to step 1710 where a broker changes load status to “on road”. After performing step 1710 , the process proceeds to step 1711 where the load status on the system actually changes to “on road”. After performing step 1711 , the process proceeds to step 1712 where “on road” hooks are fired. After performing step 1712 , the process proceeds to step 1713 where the load status changed to “load delivered”. After performing step 1713 , the process proceeds to step 1714 where “load delivered” hooks are fired. After performing step 1714 , the load is marked “BOL received”. After performing step 1715 , the process proceeds to step 1716 where “BOL received” hooks are fired. After performing step 1716 , the process proceeds to step 1717 where broker privileges are changed to “view only” status. After step 1717 , the process is terminated.
[0081] As detailed in FIG. 17 , the disclosed system provides for account management and accountability for brokers. First, account representatives (or brokers) cannot modify a load after it has been delivered. Secondly, all management of load after delivery is shifted to other departments. For example, after the shift (or lock-out), an exemplary account representative will only be enabled with the ability to view load and account information. Thirdly, only the accounting department can close a load after it has been delivered. Finally, only an administrator can modify the load outside of the normal flow process. A normal flow process for a brokered process proceeds sequentially, as follows: created ->submitted to boards->carriers add bids->broker approves carrier->load on road->load delivered->BOL (Bill of Lading) received->load closed (after billing). A normal flow process for a dispatched customer's flow process proceeds sequentially, as follows: draft->submitted to rep->submitted to boards->carriers add bids->customer approves bids->carrier signifies availability->load on road->load delivered->BOL received->load closed (after billing).
[0082] FIGS. 18A and 18B together illustrate a flowchart depicting a system for rating carriers having checks and balances in accordance with an exemplary embodiment. With reference to FIGS. 4A and 4B , a flow of logic that is executed in various embodiments, when implementing a system of checks and balances in the process of rating carriers is illustrated. The process can start at step 1800 . In step 1800 , carrier data is modified from user input or external data. After performing step 1800 , the process proceeds to step 1802 . In step 1801 , the process can start when a user selects a black flag under a carrier profile. After performing step 1801 , the process proceeds to step 1802 . In step 1802 , a carrier status update starts. After performing step 1802 , the process proceeds to step 1803 where a query is implemented to determine whether a carrier has common or contract authority. If the carrier does have authority, then the process proceeds to step 1804 . If not, the process proceeds to step 1805 . In step 1804 , a query is implemented to determine if the carrier has cargo and auto insurance. If the carrier does have the insurance, the process proceeds to step 1807 . If not, the process proceeds to step 1805 . In step 1807 , a query is implemented to determine if the carrier is flagged “black”. If the carrier has been flagged “black”, the process proceeds to step 1805 . If not, the process proceeds to step 1808 . In step 1805 , the carrier is flagged “red”. In step 1808 , a query is implemented to determine if a carrier's insurance has been internally flagged as a high risk. If so, the process proceeds to step 1809 . If not, the process proceeds to step 1811 . After performing step 1805 , the process proceeds to step 1806 where carrier bids can be added, but not approved for any load. After performing step 1808 , the process proceeds to step 1809 where a carrier is flagged “yellow”. After performing step 1809 , the process proceeds to step 1810 where a carriers updated data and status are saved to a database. In step 1811 , a query is implemented to determine if a carrier contract or common authority is pending. If so, the process proceeds to step 1809 . If not, the process proceeds to step 1812 . In step 1812 , a query is implemented to determine if carrier cargo or auto insurance will expire within “X” days (X being a determined or set number of days, such as 30 days). If so, the process proceeds to step 1809 . If not, the process proceeds to step 1813 . In step 1813 , a query is implemented to determine if a carrier has proper attached paperwork to their profile. If so, the process proceeds to step 1814 . If not, the process proceeds to step 1809 . In step 1814 , a carrier is flagged “green”. After performing step 1814 , the process proceeds to step 1816 and to step 1810 . In step 1816 , the carrier bids can be approved and they can be assigned to the load. After performing step 1816 , the process terminates. In step 1815 , a broker determines if carrier status is relevant on a case-by-case basis. After performing step 1815 , the process proceeds to step 1806 and step 1816 .
[0083] As detailed in FIG. 18 , the disclosed system provides for carrier compliance including an inter-office black list. Carriers are color coded for usability: namely, green (safe/insured), yellow (elevated risk/close to losing insurance), and red (risky/lost insurance). Notifications are provided if a particular carrier loses their insurance on a load (this data is pulled from both third-party systems and applicant's own internal management system). Such notifications are shown by item 2002 (of FIG. 20 ) and items 2110 and 2112 (of FIG. 21 ). Current logic for color coding is as follows: red is the worse case indicating no insurance; yellow is between red and green and indicates that insurance is soon at risk of loss; and green indicates insurance is in place and the carrier does not present a know risk. In addition, or optionally, black can be used to indicate that a carrier has been internally black-flagged, and should not be considered for any deliveries. If insurance is flagged due to an imminent lapse, a yellow designation is applied. If the carrier has neither common or contract authority, then a yellow designation is used. If no cargo or auto insurance is in place, a red designation is used. If cargo or auto insurance is going to expire in less than 30 days, then a yellow designation is used. All other cases will be provided with a green designation. Other suitable criteria for setting a risk-based color designation on a carrier include using information as to whether they have a W-9/EIN on file with applicant, as well as whether there is an existing contract in place with the carrier.
[0084] FIGS. 19A and 19B together illustrate a flowchart depicting logic behind selection of a temporal range in accordance with an exemplary embodiment. The process can start at step 1900 . In step 1900 , a user opens a temporal modal. After step 1900 , the process proceeds to step 1901 where a user provides input from a mouse (or input device) at a client. From step 1901 , a user proceeds to one of steps 1902 , 1906 , 1910 , 1914 , 1918 , 1921 , 1923 , 1925 , 1929 , 1933 , and 1936 . In step 1902 , the user selects “BETWEEN”. After step 1902 , the process proceeds to step 1903 where the selected type is set. After step 1903 , a query is made to determine if the dates are set. If the dates are set, the process proceeds to step 1905 where days between the set (or selected) dates are highlighted (inclusive). After step 1905 , the process proceeds to step 1901 . If the dates are not set, the process proceeds to step 1901 . In step 1906 , the user selects “BEFORE”. After step 1906 , the process proceeds to step 1907 where the selected type is set. After step 1907 , a query is made at step 1908 to determine if the dates are set. If the dates are set, the process proceeds to step 1909 where days before the set (or selected) end date are highlighted (inclusive). After step 1909 , the process proceeds to step 1901 . If the dates are not set, the process proceeds to step 1901 . In step 1910 , the user selects “AFTER”. After step 1910 , the process proceeds to step 1911 where the selected type is set. After step 1911 , a query is made at step 1912 to determine if the dates are set. If the dates are set, the process proceeds to step 1913 where days after the set (or selected) start date are highlighted (inclusive). After step 1913 , the process proceeds to step 1901 . If the dates are not set, the process proceeds to step 1901 .
[0085] In step 1914 , the user selects “AT”. After step 1914 , the process proceeds to step 1915 where the selected type is set. After step 1915 , a query is made at step 19126 to determine if the dates are set. If the dates are set, the process proceeds to step 1917 where only the start date is highlighted (inclusive). After step 1917 , the process proceeds to step 1901 . If the dates are not set, the process proceeds to step 1901 .
[0086] In step 1918 , the user selects “N/A” (not available). After step 1918 , the process proceeds to step 1919 where the selected type is set. After step 1919 , the process proceeds to step 1920 where all highlights are removed. After step 1920 , the process proceeds to step 1901 .
[0087] In step 1921 , the user selects “USE TIME”. After step 1921 , the process proceeds to step 1922 where the display of time input is toggled. After step 1922 , the process proceeds to step 1901 .
[0088] In step 1923 , the user selects a time input. After step 1923 , the process proceeds to step 1924 where the user inputs time. After step 1924 , the process proceeds to step 1901 .
[0089] In step 1925 , the user selects or clicks on a date. After step 1925 , the process proceeds to step 1926 where type is set to “AT”. After step 1926 , the process proceeds to step 1927 where start is set to the date selected. After step 1927 , the process proceeds to step 1928 where only the start date is highlighted. After step 1928 , the process proceeds to step 1901 .
[0090] In step 1929 , the user clicks and drags between two dates. After step 1929 , the process proceeds to step 1930 where the type is set to “BETWEEN”. After step 1930 , the process proceeds to step 1931 where a user sets start and end to first and last dates selected. After step 1931 , the process proceeds to step 1932 where days between selected dates are highlighted. After step 1932 , the process proceeds to step 1901 .
[0091] In step 1933 , the user selects “OK”. After step 1933 , the process proceeds to step 1934 where a temporal timeframe string is prepared. After step 1934 , the process proceeds to step 1935 where the timeframe string is passed to a parent object. After step 1935 , the process proceeds to step 1937 where the modal is closed.
[0092] In step 1936 , the user selects “CANCEL”. After step 1936 , the process proceeds to step 1937 where the modal is closed.
[0093] FIG. 20 illustrates a screen shot for a carrier profile for “FDC Enterprises LLC” to access through one or more interfaces the features and functionality of FIG. 1 in accordance with an exemplary embodiment. More particularly, the carrier profile of FIG. 20 shows
[0094] FIG. 21 illustrates an account manager/broker screen shot depicting a load profile with quotes attached to a load with carrier ratings. More particularly,
[0095] FIG. 22 illustrates an account manager/broker screen shot depicting a menu for interacting with a carrier rate on a load menu. Multiple quotes from unique sources (indicated by carriers 2106 and 2108 ) are shown, as further previously depicted by reference numeral 408 of FIG. 4B . More particularly, a note text field 2202 enables a user to input comments relating to that carrier bid and a selectable “Approve” button 2204 and “Decline” button 2206 enable a user to indicate approval or decline of a particular carrier bid.
[0096] FIG. 23 illustrates a broker-side screen shot depicting a customer profile. More particularly, an “Account” type display field 2302 is shown above a “Loads” type display field 2308 . Field 2302 includes an “Account Type” field category 2304 with a presently displayed “Fully Brokered” field value, or visual indicia that is further represented by one of a series of vehicle representations by vehicle icon 2305 . Field 2304 correlates with item 406 in FIG. 4A .
[0097] FIG. 24 illustrates a broker-side screen shot depicting a brand new load. A cursor is “moused-over” a preferred equipment “Unspecified” field 2402 which generates pop-up menu 2502 in FIG. 25 , below.
[0098] FIG. 25 illustrates a screen shot depicting the selection of equipment for the new load depicted in FIG. 25 . More particularly, pop-up menu 2502 depicts a list of unique trailer types that can be selected by a user via menu 2502 . The list of unique trailer types is queried from a database of industry standard trailer types and transportation methods (including intermodal). A search box field 2504 is also provided for inputting and searching the database for a specific type of trailer or transportation method.
[0099] FIG. 26 illustrates a screen shot depicting a new load and adding a new line item to a customer's invoice. More particularly, a pop-up menu 2602 is used to add a line item to a customer invoice based on industry-specific needs. The data input via menu 2602 is automatically provided as input into an accounting management program, such as Quick Books™.
[0100] FIG. 27 illustrates a screen shot depicting realization of the line item added to the customer's invoice of FIG. 26 . More particularly, “Tarp/Tailgate” field 2702 has been added along with a value field entry 2704 of $150.
[0101] FIG. 28 illustrates a screen shot depicting the ability to add a shipper and a receiver for a designated city and state. A “Route” data entry field 2802 is provided with a “Shipper” data entry field 2804 and a “Receiver” data entry field 2806 . Shipper waypoint location and load information is entered by a user into field 2804 . Receiver waypoint location and load information is entered by a user into field 2806 .
[0102] FIG. 29 illustrates a screen shot depicting a pop-up menu 2902 while selecting a temporal date range. More particularly, a “Between” date range selection feature 2904 has been selected to enable a single tactile input gesture (such as click-and-drag operation) for selecting a range of dates.
[0103] FIG. 30 illustrates a screen shot depicting the pop-up menu 2902 of FIG. 29 while selecting a temporal time range. A selected date range is shown for a “Shipper” as subsequently depicted in FIG. 32 . Encircled “5” indicates the present date.
[0104] FIG. 31 illustrates a screen shot depicting the pop-up menu 2902 of FIGS. 29 and 30 while selecting a temporal “after” time range 3104 shown for a “Reciever” as subsequently depicted in FIG. 32 . More particularly, all dates after (and including) Feb. 19, 2014 are selected.
[0105] FIG. 32 illustrates a screen shot depicting a realized selected temporal range implemented via actions depicted in FIGS. 29-31 . A selected date range 3202 and 3204 is shown for both the “Shipper” and the “Receiver”, respectively. Additionally, a “Weight” data entry field 3206 has received an input of “3T” (lb.).
[0106] FIG. 33 illustrates a screen shot depicting automatically converted units of weight for a specific cargo over that entered in the screen shot of FIG. 32 . “Weight” data entry field 3206 has been automatically converted in units (from tons) into pounds (lb.). Additionally, automatic conversions of units, such as English and metric unit measures are implemented via such system and feature. Finally, a cursor 3201 is “moused-over” “POST TO LOAD BOARD” button which triggers posting of the input information to the load board.
[0107] FIG. 34 illustrates a screen shot depicting a load status change “PUT ON HOLD” designated by item 3402 resulting from selection of a “POST TO LOAD BOARDS” field 3203 (in FIG. 33 ). Further details of the load status change are provided in FIG. 17 , above.
[0108] FIG. 35 illustrates a screen shot depicting the adding of a carrier quote where permissions change the rate and “XYZ TRUCKING” is added. A notifications message window 3502 is shown after selecting “Notifications” selection item 3504 .
[0109] FIG. 36 illustrates a screen shot depicting the addition of a second carrier quote indicated by reference item 3602 to provide for multiple quotes. Item 3602 represents a rate of $3,500 for “XYZ Transport” which comprises an “Open Quote”.
[0110] FIG. 37 illustrates a screen shot depicting a carrier quote menu. More particularly, a cursor 3701 is “moused-over” a “No Equipment Specified” menu selection item 3702 which causes pop-up menu 3802 to be enabled in FIG. 38 .
[0111] FIG. 38 illustrates a screen shot depicting a pop-up menu for adding carrier quote equipment. More particularly, pop-up menu 3802 depicts a list of unique trailer types that can be selected by a user via menu 3802 . The list of unique trailer types is queried from a database of industry standard trailer types and transportation methods (including intermodal). A search box field is also provided for inputting and searching the database for a specific type of trailer or transportation method.
[0112] FIG. 39 illustrates a screen shot depicting realized changes of carrier quote equipment type from actions taken by a user depicted previously in FIG. 37 and FIG. 38 .
[0113] FIG. 40 illustrates a screen shot depicting the addition of a note to a carrier. More particularly, “XYZ Trucking” text input field 4002 includes a note input field 4004 in which indicia, or text 4006 has been input by a user.
[0114] FIG. 41 illustrates a screen shot depicting realization of the added note input in FIG. 40 .
[0115] FIG. 42 illustrates a screen shot depicting realizing equipment changes for the listed carrier with the added note and approval of “XYZ TRUCKING”. A cursor 4201 is “moused-over” an “Approved” selection button, when clicked, causes the identified carrier to be approved on the load. A “Decline” selection button 4204 is also provided for declining that carrier.
[0116] FIG. 43 illustrates a screen shot depicting realized changes for approved carrier “XYZ TRUCKING” resulting from selection of “Approved” selection button 4204 (in FIG. 42 ). In addition, a “Carrier” field 4302 now shows “XYZ Trucking”. An “Equipment” field 4304 shows “Cargo Van”. A carrier pay field 4306 shows “$3,900”.
[0117] FIG. 44 illustrates a screen shot depicting creation of carrier rate paperwork. By selecting a lock icon 4308 above carrier pay field 4306 using cursory 4401 , it creates paperwork as shown below with reference to FIGS. 45 and 46 .
[0118] FIG. 45 illustrates a screen shot depicting a pop-up screen 4502 that provides a secondary check to a user indicating that this operation is desired by the user. A user is presented with an “OK” selection button 4504 and a “Cancel” selection button 4506 for respectively launching or cancelling the “lock” to respective system data and limits the ability for values to be changed, such as permission-locking user access to only administrative or broker level personnel (other users will be prevented from unlocking the data and making changes).
[0119] FIG. 46 illustrates a screen shot depicting realization of carrier rate confirmation paperwork which is triggered as a result of selecting “OK” button 4504 in FIG. 45 . As a result, “Paperwork” menu portion 4602 is shown having an added “Carrier Rate Confirmation” item 4604 . A carrier pay rate item 4606 is also provided as “$3,900”.
[0120] FIG. 47 illustrates a screen shot depicting realization of customer rate confirmation paperwork. A cursor is shown selecting item 4606 which, in a locked state, generates a “disabled feature” icon 4702 .
[0121] FIG. 48 illustrates a screen shot depicting selection of change of load status to “IN TRANSIT”. A cursor 4801 is shown selecting “MOVE TO IN TRANSIT” button 4802 which causes a screen display change represented below in FIG. 49 .
[0122] FIG. 49 illustrates a screen shot depicting realization of selection of the changed load status in FIG. 48 . A “MOVE TO DELIVERED” button 4902 is then provided for selection by a user.
[0123] FIG. 50 illustrates a screen shot depicting added notes to a load with carrier permissions to view. A cursory 5001 is provided (hovers) over a carrier note permissions icon 5002 . A tool tips, or pop-up box 5004 is generated to display the current carrier note permissions status.
[0124] FIG. 51 illustrates a screen shot depicting that selection is being to enable viewing by the carrier of note text.
[0125] In compliance with the statute, the subject matter disclosed herein has been described in language more or less specific as to structural and methodical features. It is to be understood, however, that the claims are not limited to the specific features shown and described, since the means herein disclosed comprise example embodiments. The claims are thus to be afforded full scope as literally worded, and to be appropriately interpreted in accordance with the doctrine of equivalents. | An apparatus is provided for improved processing of instructions to provide temporal selection to a client when scheduling a load to be transported for a prospective transportation industry customer. The apparatus includes a processor and a non-transitory machine readable memory. The processor is designed to process instructions to provide date and time selection to a client from a server to enable temporal scheduling of a load to be transported for a prospective transportation industry customer. The non-transitory machine readable memory at a host server has stored therein computer instructions programmed to cause the processor to store and access user information and instructions, and to present, enable, receive, store and associate date ranges, time ranges and waypoints for a load and cargo delivery destination. A method is also provided. | 53,970 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an electron microscope and also to a method of operating it.
[0003] 2. Description of Related Art
[0004] Generally, electrons emitted from a field-emission electron gun contain a varying portion of several percent for the following reason. Gases and ions are adsorbed onto the surface of the emitter and migrate, varying the work function of the metal surface. Also, collision of ions and so on varies the geometry of the metal surface. Therefore, where a field-emission electron gun is used in a scanning transmission electron microscope (STEM), a detector for noise cancellation is mounted in the electron optical column to detect nearby electrons that form a probe. The signal emitted from the sample is divided by the resulting detection signal, whereby emission noise on the image is eliminated. This noise canceling technique is disclosed, for example, in JP-A-5-307942.
[0005] FIG. 15 shows the configuration of a scanning transmission electron microscope (STEM) 101 having a general noise cancellation function. This electron microscope 101 of FIG. 15 has an electron optical column 110 in which various components including a cold field-emission electron gun (CFEG) 111 , a noise canceling aperture 112 , a lens 113 a, scan coils 113 b, another lens 114 , a detector 115 , a preamplifier circuit 120 , and an amplifier circuit 130 are housed.
[0006] The electron beam emitted from the CFEG 111 is partially cut off by the noise canceling aperture 112 and then converged onto a sample A by the lens 113 a. The converged beam is scanned over the sample A by the scan coils 113 b. The electron beam transmitted through the sample A passes through the lens 114 , and a part of the beam is detected by the detector 115 .
[0007] An image signal detected by the detector 115 is the product of an emission current I 1 impinging on the sample A and the brightness component S of the sample A, i.e., I 1 ×S. The emission current I 1 impinging on the sample A and the emission current I 2 detected by the noise canceling aperture 112 have a proportional relationship, i.e., I 1 =n×I 2 . An offset is added to the image signal (I 1 ×S) and the resulting signal is amplified by a factor of Gp by the preamplifier circuit 120 . The amplified signal is further amplified by a factor of Ga by the amplifier circuit 130 .
[0008] On the other hand, the emission current I 2 detected by the noise canceling aperture 112 is amplified by a factor of Gn by a noise detection circuit 140 . When the noise cancellation function is not used, the output signal of the amplifier circuit 130 bypasses a noise canceling circuit 150 and is arithmetically processed in a given manner by an arithmetic section (CPU) 160 and then sent to a personal computer (PC) 102 . As a result, an STEM image of the sample A is displayed on a display unit for use with the PC 102 .
[0009] When the noise cancellation function is used, the offset component added by the preamplifier circuit 120 is subtracted from the output signal of the amplifier circuit 130 by the noise canceling circuit 150 . Then, the resulting signal is divided by the output signal of the noise detection circuit 140 . Consequently, the emission noise contained in the image signal is removed. The image signal free of the emission noise is arithmetically processed in a given manner by the arithmetic section (CPU) 160 and sent to the personal computer (PC) 102 . An STEM image of the sample A free of the emission noise is displayed on the display unit for use with the PC 102 .
[0010] FIG. 16 shows a specific example of configuration of signal processing circuitry when the electron microscope 101 is in a mode of operation where the noise cancellation function is not used. As shown in this figure, when the noise cancellation function is not in use, STEM imaging is done fundamentally using only two adjustments, i.e., contrast and brightness. Contrast is a gain added to an image signal for adjusting the brightness. Brightness is a DC voltage applied to cancel out the offset component of the image signal. In the example of FIG. 16 , with respect to the image signal S×I 1 obtained from the detector 115 by adjusting the contrast, brightness B is added to the image signal S×I 1 by an adder 122 in the preamplifier circuit 120 and then amplified by the factor of Gp by an amplifier 124 . Therefore, the output signal V 11 of the amplifier 124 is given by
[0000] V 11 =Gp ×( S×I 1 +B ) (A)
[0011] The output signal V 11 of the amplifier 124 is amplified by the factor of Ga by an amplifier 132 in the amplifier circuit 130 . Thus, from Eq. (A) above, the output signal V 12 of the amplifier 132 is given by
[0000] V 12 =Ga×Gp ×( S×I 1 +B ) (B)
[0012] The output signal V 12 of the amplifier 132 is converted from analog to digital form by an analog to digital converter (ADC) 162 in the arithmetic section 160 , then averaged or otherwise arithmetically processed, and sent to the PC 102 shown in FIG. 15 .
[0013] On the other hand, FIG. 17 shows a specific example of configuration of signal processing circuitry when the electron microscope 101 is in a mode of operation where the noise cancellation function is used. As shown in this figure, also when the noise cancellation function is used, the output signal V 12 of the amplifier 132 is given by Eq. (B) above. In order to cancel out the brightness B added by the preamplifier circuit 120 , an amplifier 151 of the noise canceling circuit 150 adds a gain equal to the product of the gain Gp of the amplifier 124 and the gain Ga of the amplifier 132 to the brightness B. A subtractor 152 subtracts the output of the amplifier 151 from the output signal V 12 of the amplifier 132 . Accordingly, it is seen from Eq. (B) above that the output signal V 13 of the subtractor 152 is given by
[0000]
V
13
=
Ga
×
Gp
×
(
S
×
I
1
+
B
)
-
Ga
×
Gp
×
B
=
Ga
×
Gp
×
S
×
I
1
(
C
)
[0014] The emission current I 2 detected by the noise canceling aperture 112 is converted into a voltage and amplified by the factor of Gn by an amplifier 142 in the noise detection circuit 140 . Therefore, the output signal V 14 of the amplifier 142 is given by
[0000] V 14 =Gn×I 2 (D)
[0015] The output signal V 13 of the subtractor 152 is applied to a numerator input (X) of a divider circuit 154 . The output signal V 14 of the amplifier 142 is applied to a denominator input (Y) of the divider circuit 154 . Accordingly, from Eqs. (C) and (D), the output signal V 15 of the divider circuit 154 is given by
[0000]
V
15
=
X
Y
=
V
13
V
14
=
Ga
×
Gp
×
S
×
I
1
Gn
×
I
2
(
E
)
[0016] In the noise canceling circuit 150 , in order to subtract the output signal of the amplifier 151 from the output signal V 12 of the amplifier 132 by the subtractor 152 , an amplifier 155 adds a gain equal to the product of the gain Gp of the amplifier 124 and the gain Ga of the amplifier 132 to the brightness B. An adder 156 adds the output of the amplifier 155 to the output signal V 15 of the divider circuit 154 . Therefore, the output signal V 16 of the adder 156 is given by
[0000]
V
16
=
Ga
×
Gp
×
S
×
I
1
Gn
×
I
2
+
Ga
×
Gp
×
B
=
S
×
Ga
×
Gp
Gn
×
I
1
I
2
+
Ga
×
Gp
×
B
(
F
)
[0017] The output signal V 16 of the adder 156 is converted from analog to digital form by the analog to digital converter 162 in the arithmetic section 160 , then averaged or otherwise arithmetically processed, and sent to the PC 102 shown in FIG. 15 .
[0018] Substituting the equation, I 1 =n×I 2 , into Eq. (F) results in
[0000]
V
16
=
S
×
Ga
×
Gp
Gn
×
n
+
Ga
×
Gp
×
B
(
G
)
[0019] Note that none of the emission currents I 1 and I 2 containing emission noise are present in the right side of Eq. (G). Consequently, when the noise cancellation function is used, a value proportional to the brightness component S of the sample S to be imaged and observed is obtained in the same way as when there is no emission noise.
[0020] In the example of FIG. 17 , operations for removing and re-adding brightness and a division operation are performed by analog circuitry. Alternatively, these operations may be carried out by digital arithmetic operations. In this case, measurement and setting of the gain of brightness that is removed and re-added and other adjustments can be made automatically.
[0021] The related art noise canceling method described so far has the following problems.
[0022] First, where the division is performed with an analog circuit (herein referred to as the analog division method), it is necessary to constitute log (logarithm) circuits and an antilog circuit. FIG. 18 shows one example of configuration of the divider circuit 154 using log circuits 154 a, 154 b and an antilog circuit 154 c. As shown in FIG. 18 , the divider circuit 154 performs a division using analog signals by performing a logarithmic conversion by the log circuits 154 a, 154 b, then subtracting the output signal of the log circuit 154 b from the output signal of the log circuit 154 a, and performing a logarithmic conversion of the resulting difference by the antilog circuit 154 c.
[0023] In the analog division method, it is necessary to constitute the log circuits 154 a, 154 b and antilog circuit 154 c operating in a frequency bandwidth of several MHz corresponding to the speed at which the image signal is detected and so the amount of noise component increases steeply. However, this frequency bandwidth is required for signals of STEM images and, therefore, it is difficult to limit the bandwidth subsequently. The antilog circuit 154 c has a high gain, and it is difficult to broaden the frequency bandwidth due to the effects of noise.
[0024] On the other hand, where divisions are performed by digital computations (herein referred to as the digital division method), divisions are slower to perform than other types of calculations. As a result, the frequency bandwidth is narrowed.
SUMMARY OF THE INVENTION
[0025] The present invention has been made in view of the foregoing problems. One object associated with some aspects of the present invention is to provide an electron microscope capable of implementing a noise cancellation process which achieves a low level of noise and which can be operated at high speed. Another object is to provide a method of operating this electron microscope.
[0026] (1) An electron microscope associated with the present invention comprises: an electron beam source for producing an electron beam; a noise detector for detecting a part of the electron beam to thereby produce a beam detection signal and dividing a dividend by the beam detection signal; at least one image signal detector for detecting an image signal obtained by making the electron beam impinge on a sample; and an arithmetic section for performing a multiplication between an output signal of the image signal detector and an output signal of the noise detector.
[0027] In this electron microscope, the dividend is divided by the beam detection signal in the noise detector. The image signal is detected by the image signal detector. The arithmetic section performs a multiplication between the output signal of the noise detector and the output signal of the image signal detector. Consequently, the image signal neither passes through any divider circuit nor undergoes a division operation relying on digital computations. This makes it unnecessary for the noise detector to constitute a divider circuit having a frequency bandwidth, for example, corresponding to the speed at which an image signal is detected. Hence, noise can be suppressed. Furthermore, the image signal detector can be made higher in operation without being limited by the speed at which a division operation is performed. Thus, this electron microscope can achieve a noise cancellation process which results in a low level of noise and which can be implemented at high speed.
[0028] (2) In one feature of this electron microscope, the arithmetic section may perform the multiplication by a digital arithmetic operation.
[0029] This electron microscope can achieve a noise cancellation process which results in a low level of noise and which can be implemented at high speed.
[0030] (3) In another feature of this electron microscope, the noise detector may include a divider circuit that divides the dividend by the beam detection signal in an analog manner.
[0031] In this electron microscope, the image signal does not pass through any divider circuit. This makes it unnecessary to constitute a divider circuit having a frequency bandwidth corresponding to the speed at which the image signal is detected. Therefore, low-noise parts having a narrow frequency bandwidth, for example, can be used to form the divider circuit. Moreover, a filter having a narrow bandwidth, for example, for suppressing noise generated from the divider circuit can be inserted. Thus, this electron microscope can achieve a noise cancellation process which results in a still lower level of noise.
[0032] (4) In a further feature of this electron microscope, the dividend may be an effective value of the beam detection signal.
[0033] With this electron microscope, images can be observed without regard to the manner in which the emission current decreases with time. Therefore, with this electron microscope, if a cold cathode field-emission electron gun is used as an electron beam source, images free of emission noise can be observed by performing operations similar to operations done when a Schottky emission gun is used.
[0034] (5) In an additional feature of this electron microscope, the at least one image signal detector may be plural in number. The arithmetic section may perform multiplications between output signals of the plural image signal detectors and the output signal of the noise detector.
[0035] In this electron microscope, divisions are performed in the noise detectors. In the arithmetic section, multiplication operations are performed without performing division operations. Therefore, in the arithmetic section, the load incurred in arithmetically processing the output signals of the image signal detectors can be reduced, for example, as compared with the case where a division operation is performed on each of the output signals of the image signal detectors. Consequently, if this electron microscope has plural image signal detectors, the processing load on the arithmetic section can be reduced. When the output values from the plural image signal detectors are entered, they can be arithmetically processed in parallel and simultaneously.
[0036] (6) A method of operating an electron microscope in accordance with the present invention comprises the steps of: detecting a part of an electron beam generated by an electron beam source to thereby produce a beam detection signal and dividing a dividend by the beam detection signal (may also be referred to as the noise detecting step); making the electron beam impinge on a sample to produce an image signal and detecting the image signal (may also be referred to as the image signal detecting step); and performing a multiplication between an output signal produced from the image signal detecting step and an output signal produced from the noise detecting step (may also be referred to as the computing step).
[0037] In this method of operating an electron microscope, during the noise detecting step, the dividend is divided by the beam detection signal. During the image signal detecting step, the image signal is detected. During the computing step, a multiplication between the output signal produced from the noise detecting step and the output signal produced from the image signal detecting step is performed. As a result, the image signal neither passes through any divider circuit nor undergoes a division operation relying on digital computations. Consequently, in this method of operating an electron microscope, a noise cancellation process which results in a low level of noise and which can be performed at high speed can be accomplished.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1 is a block diagram of an electron microscope associated with a first embodiment of the present invention.
[0039] FIG. 2 is a block diagram of one specific example of signal processing circuitry included in the microscope shown in FIG. 1 .
[0040] FIGS. 3A-3C are waveform diagrams of signals appearing at nodes of an image signal detector included in the microscope shown in FIG. 1 .
[0041] FIGS. 4A-4D are waveform diagrams of signals appearing at nodes of a noise detector included in the microscope shown in FIG. 1 .
[0042] FIG. 5 is a waveform diagram showing one example of how emission current varies with time.
[0043] FIG. 6A is a waveform diagram of a noise signal.
[0044] FIG. 6B is a waveform diagram of one example of the output signal of an effective value computing circuit.
[0045] FIG. 7 is a block diagram of one specific example of signal processing circuitry according to a first modification of the first embodiment.
[0046] FIG. 8 is a block diagram of one specific example of signal processing circuitry according to a second modification of the first embodiment.
[0047] FIG. 9 is a block diagram of one specific example of signal processing circuitry according to a third modification of the first embodiment.
[0048] FIG. 10 is a block diagram of an electron microscope associated with a second embodiment of the present invention.
[0049] FIG. 11 is a diagram of a multi-segmented STEM detector for use in the electron microscope shown in FIG. 10 .
[0050] FIG. 12 is a block diagram of one specific example of signal processing circuitry included in the microscope shown in FIG. 10 .
[0051] FIG. 13 is a block diagram of an electron microscope associated with a third embodiment of the invention.
[0052] FIG. 14 is a block diagram of one specific example of signal processing circuitry included in the microscope shown in FIG. 13 .
[0053] FIG. 15 is a block diagram of a scanning transmission electron microscope (STEM) having a general noise cancellation function.
[0054] FIG. 16 is a block diagram of one specific example of signal processing circuitry incorporated in a conventional electron microscope, and in which the microscope is in a mode of operation where the noise cancellation function is not used and an illustration of electric circuitry associated with the noise cancellation is omitted.
[0055] FIG. 17 is a block diagram similar to FIG. 16 , but in which the microscope is in a mode of operation where the noise cancellation function is used.
[0056] FIG. 18 is a block diagram of one example of a divider circuit using log circuits and an antilog circuit.
DESCRIPTION OF THE INVENTION
[0057] The preferred embodiments of the present invention are hereinafter described in detail with reference to the drawings. It is to be understood that the embodiments provided below do not unduly restrict the scope and content of the present invention delineated by the appended claims and that not all the configurations described below are essential constituent components of the invention.
1. First Embodiment
1.1. Electron Microscope
[0058] An electron microscope associated with a first embodiment of the present invention is first described by referring to FIG. 1 , which shows one example of configuration of the electron microscope, 1 .
[0059] As shown in FIG. 1 , the electron microscope 1 is configured including an electron optical column 10 , a noise detection circuit 40 , an A/D converter 50 , and an arithmetic section (CPU) 60 . Housed in the electron optical column 10 are an electron beam source 11 , a noise canceling aperture 12 , an illumination lens system 13 a, scan coils 13 b, an imaging lens system 14 , an image detector 15 , a preamplifier circuit 20 , an amplifier circuit 30 , and so on.
[0060] In the electron microscope 1 , the noise canceling aperture 12 and the noise detection circuit 40 together constitute a noise detector 4 for detecting emission noise. Also, the image detector 15 , preamplifier circuit 20 , amplifier circuit 30 , and A/D converter 50 together constitute an image signal detector 6 for detecting an image signal (STEM image signal).
[0061] The electron microscope 1 is a scanning transmission electron microscope (STEM). Other components such as various lenses and apertures are housed in the electron optical column 10 but their description and illustration are omitted below. Some of the components of the electron microscope 1 of the present embodiment which are shown in FIG. 1 may be omitted or replaced by other parts. Also, additional components may be added to this microscope.
[0062] An electron beam emitted from the electron beam source 11 is partially cut off by the noise canceling aperture 12 and then focused onto a sample A by the lens system 13 a. The focused electron beam (also referred to as an electron probe) is scanned over the sample A by the scan coils 13 b. A well-known electron gun such as a cold cathode field-emission gun (CFEG) can be used as the electron beam source 11 .
[0063] The electron beam transmitted through the sample A passes through the lens system 14 , and a part of the beam is detected as an image signal by the image detector 15 . The image signal is the product of the emission current I 1 impinging on the sample A and the brightness component S of the sample A, i.e., I 1 ×S.
[0064] The noise canceling aperture 12 detects the emission current (noise signal). By way of example, any one (such as condenser lens (CL) apertures) of the illumination apertures disposed between the electron beam source 11 and the sample A in the electron optical column 10 may be used also as the noise canceling aperture 12 . A dedicated noise canceling aperture 12 apart from the illumination apertures may also be mounted.
[0065] The noise detection circuit 40 creates a signal for removing the emission noise from the image signal, based on the emission current 12 detected by the noise canceling aperture 12 .
[0066] The arithmetic section 60 removes (more precisely, reduces) the noise signal superimposed on the output signal of the amplifier circuit 30 that has been converted from analog to digital form by the A/D converter 50 by making use of the fact that there is a proportional relationship between the emission current I 1 impinging on the sample A and the emission current I 2 detected by the noise canceling aperture 12 (i.e., I 1 =n×I 2 , where n is a proportional constant). Then, the signal free of the noise signal is arithmetically processed in a given manner by the arithmetic section 60 and then sent to the personal computer (PC) 2 . An STEM image of the sample A is displayed on the display unit for use with the PC 2 and stored in it.
1.2. Signal Processing Circuitry of the Electron Microscope
[0067] FIG. 2 shows a specific example of configuration of signal processing circuitry for use in the electron microscope according to the first embodiment. In FIG. 2 , those components or configurations which are identical to their respective counterparts shown in FIG. 1 are indicated by the same reference numerals as in FIG. 1 .
[0068] In the present embodiment, the image signal detector 6 is configured including the image detector 15 , preamplifier circuit 20 , amplifier circuit 30 , and A/D converter 50 . FIGS. 3A-3C show examples of signal waveform at various nodes of the image signal detector 6 of FIG. 2 .
[0069] In the present embodiment, the preamplifier circuit 20 is configured including an adder 22 and an amplifier 24 .
[0070] The image signal S×I 1 (see FIG. 3A ) obtained from the image detector 15 by adjusting the contrast is amplified by a factor of Gp by the amplifier 24 after brightness B is added by the adder 22 . Therefore, the output signal of the amplifier 24 (i.e., the output signal of the preamplifier circuit 20 ) V 1 (see FIG. 3B ) is given by
[0000] V 1 =Gp ×( S×I 1 +B ) (1)
[0071] Contrast is a gain added to the image signal to adjust the degree of brightness. In the present embodiment, contrast is set for the image detector 15 . Brightness is a DC voltage applied to cancel out the offset component of the image signal. In the present embodiment, brightness is set for the preamplifier circuit 20 .
[0072] In the present embodiment, the amplifier circuit 30 is configured including an amplifier 32 . The output signal V 1 of the preamplifier circuit 20 is amplified by a factor of Ga by the amplifier 32 . Therefore, from Eq. (1), the output signal V 2 of the amplifier 32 (i.e., the output signal of the amplifier circuit 30 ) (see FIG. 3C ) is given by
[0000] V 2 =Ga×Gp ×( S×I 1 +B ) (2)
[0073] The output signal V 2 of the amplifier circuit 30 is converted from analog to digital form by the A/D converter 50 and applied to the arithmetic section 60 .
[0074] In the present embodiment, the noise detector 4 is configured including the noise canceling aperture 12 and the noise detection circuit 40 . FIGS. 4A-4D show examples of signal waveform at various nodes of the noise detector 4 of FIG. 2 .
[0075] The noise detection circuit 40 is configured including an amplifier 42 , an effective value computing circuit 44 , a divider circuit 46 , and an A/D converter 48 .
[0076] The amplifier 42 converts the emission current I 2 (see FIG. 4A ) detected by the noise canceling aperture 12 into a voltage and amplifies it by a factor of Gn. Therefore, the output signal (noise signal) V 3 (see FIG. 4B ) of the amplifier 42 is given by
[0000] V 3 =Gn×I 2 (3)
[0077] The effective value computing circuit 44 calculates the effective (RMS (root mean square)) value of the output signal V 3 of the amplifier 42 in real time within a preset time. For example, a general-purpose IC may be used as the effective value computing circuit 44 .
[0078] The output signal (Gn×I 2 ) RMS (see FIG. 4C ) of the effective value computing circuit 44 is applied to the numerator input (X) of the divider circuit 46 , and the output signal V 3 of the amplifier 42 is applied to the denominator input (Y). The divider circuit 46 performs a division of the former signal by the latter. Thus, the output signal V 4 (see FIG. 4D ) of the divider circuit 46 is given by
[0000]
V
4
=
X
Y
=
(
Gn
×
I
2
)
RMS
Gn
×
I
2
(
4
)
[0079] As one example, an analog circuit (see, for example, FIG. 18 ) configured including log circuits and an antilog circuit can be used as the divider circuit 46 . That is, in the noise detector 4 , the divider circuit 46 divides the output signal of the effective value computing circuit 44 by the output signal of the amplifier 42 in an analog manner (i.e., a division using analog signals).
[0080] The output signal V 4 of the divider circuit 46 is converted from analog to digital form by the A/D converter 48 and applied to the arithmetic section 60 .
[0081] An offset is applied to the image signal by the preamplifier circuit 20 , and the resulting signal is amplified by the amplifiers 24 and 32 to value (Gp×Ga×B). The arithmetic section 60 subtracts this value (Gp×Ga×B) from the output value of the A/D converter 50 using a digital computation. Consequently, brightness can be removed from the output value of the image signal detector 6 .
[0082] The arithmetic section 60 performs a multiplication operation between the output value (Ga×Gp×S×I 1 ) of the image signal detector 6 from which brightness has been removed and the output value ((Gn×I 2 ) RMS /(Gn×I 2 )) of the A/D converter 48 . The result of this multiplication operation is given by
[0000]
Ga
×
Gp
×
S
×
I
1
×
(
Gn
×
I
2
)
RMS
Gn
×
I
2
=
Ga
×
Gp
×
S
×
n
×
(
Gn
×
I
2
)
RMS
Gn
(
5
)
[0000] where I 1 =n×I 2 .
[0083] The emission currents I 1 and I 2 containing emission noise do not exist in the right side of Eq. (5) above. In this way, a value proportional to the brightness component S of the sample A to be imaged and observed is obtained using the noise cancellation function in the same way as when there is no emission noise.
[0084] Using a DC component I 2 DC and a noise component N, the emission current I 2 is given by
[0000] I 2= I 2 Dc +N (6)
[0085] The output signal (Gn×I 2 ) RMS of the effective value computing circuit 44 can be approximated by
[0000] ( Gn×I 2) RMS =Gn ×( I 2) RMS ≅Gn×I 2 DC (7)
[0086] Therefore, if Eqs. (6) and (7) are substituted into Eq. (5), the result of the multiplication operation, i.e., product, is approximated by
[0000]
Ga
×
Gp
×
S
×
n
×
(
Gn
×
I
2
)
RMS
Gn
=
∼
Ga
×
Gp
×
S
×
n
×
(
Gn
×
I
2
DC
)
Gn
=
Ga
×
Gp
×
S
×
n
×
I
2
DC
(
8
)
[0087] In Eq. (8), I 2 DC is an ideal DC current obtained by removing noise component N from the emission current I 2 and is an emission current detected when there is no emission noise. The equation, I 1 =I 2 ×n, leads to the fact that I 2 DC ×n corresponds to the ideal DC current I 1 DC obtained by removing emission noise from the emission current I 1 .
[0088] Accordingly, if the equation, I 2 DC ×n=I 1 DC , is substituted into Eq. (8), the result of the multiplication operation performed by the arithmetic section 60 is approximated by
[0000] Ga×Gp×S×n×I 2 DC =Ga×Gp×S×I 1 DC (9)
[0089] After performing the above-described multiplication operation, the arithmetic section 60 adds the previously subtracted product (Ga×Gp×B) to the result of the multiplication (see Eq. (9)) using a digital computation. Consequently, brightness is re-added. The result of the addition operation is given by
[0000] Ga×Gp×S×I1 DC +Ga×Gp×B=Ga×Gp ×( S×I 1 DC +B ) (10)
[0090] The arithmetic section 60 averages or otherwise arithmetically processes the result of re-addition of brightness (see Eq. (10) above) using a digital computation to generate image data and sends the image data to the PC 2 shown in FIG. 1 . The PC 2 receives the image data generated by the arithmetic section 60 , writes the data into a frame buffer, displays an STEM image of the sample A, from which emission noise has been removed or reduced, on the display unit, stores the image, and performs other processing.
[0091] The value of the ideal DC current I 1 DC of Eq. (10) above is nearly equal to the emission current impinging on the sample A when there is no emission noise. Consequently, an STEM image can be observed by adjusting only two parameters, i.e., contrast and brightness, while maintaining constant Ga, Gp, Gn and the gain added to brightness that is removed and re-added.
[0092] If the emission current decreases with time as shown in FIG. 5 , the signal applied to the arithmetic section 60 always assumes the form given by Eq. (10). It is possible to continue to obtain a signal that is equal to the output signal V 2 of the amplifier circuit 30 (given by Eq. (2)) from which only noise has been removed.
[0093] Where the electron microscope 1 can switch on and off the noise cancellation function in an unillustrated manner, Eq. (10) representing the output signal of the arithmetic section 60 is similar to Eq. (2) representing the signal applied to the arithmetic section 60 when the noise cancellation function is deactivated except that the emission current I 1 of Eq. (2) is replaced by I 1 DC . Therefore, it is not necessary to perform cumbersome operations whenever the noise cancellation function is switched on or off.
[0094] The electron microscope 1 associated with the present embodiment has the following features.
[0095] In the electron microscope 1 , the effective value of a noise signal is divided by the noise signal by means of the divider circuit 46 in the noise detector 4 . An image signal is detected in the image signal detector 6 . In the arithmetic section 60 , a multiplication between the output signal of the noise detector 4 and the output signal of the image signal detector 6 is performed. Thus, the image signal does not pass through the divider circuit 46 .
[0096] As an example, where an image signal passes through a divider circuit, if an analog division is used, then it is necessary to constitute log and antilog circuits having frequency bandwidths of several MHz corresponding to the speed at which the image signal is detected. This presents the problem that the noise component is increased greatly. Furthermore, if a digital division is used, this division is slower to perform than other types of arithmetic operations with the consequent result that the frequency bandwidth is narrowed.
[0097] In the electron microscope 1 , as described previously, an image signal does not pass through any divider circuit. This makes it unnecessary to form a divider circuit, for example, having a frequency bandwidth of several MHz corresponding to the speed at which the image signal is detected; otherwise, noise in the divider circuit would not be suppressed. Furthermore, in the electron microscope 1 , the speed of operation of the image signal detector 6 can be enhanced without being limited by the speed at which division operations are processed. Therefore, in the electron microscope 1 , the foregoing problems do no occur. Hence, noise canceling which results in a low level of noise and which can be implemented at high speed can be accomplished.
[0098] Furthermore, in the electron microscope 1 , the divider circuit 46 included in the noise detector 4 divides the effective value of the noise signal by the noise signal in an analog manner. As described above, the image signal does not pass through any divider circuit in the electron microscope 1 and so components making up the divider circuit 46 can be made separate from components making up the image signal detector 6 . Consequently, low-noise parts having narrow frequency bandwidths can be used as the components making up the divider circuit 46 . As a result, noise cancellation yielding a still lower level of noise can be accomplished.
[0099] In this way, in the electron microscope 1 , the image signal detector 6 needing a bandwidth higher than several MHz and the noise detector 4 used in a frequency bandwidth up to several MHz are separated from each other by analog circuitry. As a consequence, noise cancellation which results in a low level of noise and which can be implemented at high speed can be accomplished.
[0100] In the electron microscope 1 , the effective value of a noise signal is computed by the effective value computing circuit 44 and used as a dividend used in the divider circuit 46 . This permits images to be observed without regard to the manner in which the emission current decreases with time as described previously. Therefore, in the electron microscope 1 , if a cold cathode field-emission, electron gun (CFEG) is used as the electron beam source 11 , images free from emission noise can be observed by performing operations similar to operations performed on a Schottky emission gun.
[0101] As shown in FIG. 6A , the output signal (noise signal) of the amplifier 42 contains long-term emission noises (low-frequency noises) (noises appearing during an interval from t 1 to t 2 in FIG. 6A ) affecting plural successive lines of image and short-term emission noises (high-frequency noises) affecting only one line. Therefore, in the effective value computing circuit 44 , as the computation time to compute the effective value is reduced, the result of the computation of the effective value varies to a greater extent. As a result, the noise canceling performance will deteriorate.
[0102] The computation time taken for the effective value computing circuit 44 to compute the effective value is preferably set longer than, for example, the time (several seconds) taken for the PC 2 to obtain one page of image (STEM images) of the sample A. In this case, even if there is long-term noise, for example, persisting from t 1 to t 2 as shown in FIG. 6A , the output signal of the effective value computing circuit 44 varies only a little during the period from t 1 to t 3 as shown in FIG. 6B . In consequence, the noise canceling performance will hardly deteriorate.
1.3. Modifications of Electron Microscope
[0103] Modifications of the electron microscope associated with the present embodiment are next described. Only the differences with the above-described example of the electron microscope 1 shown in FIGS. 1 and 2 are described; a description of similarities is omitted.
(1) First Modification
[0104] A first modification is first described. FIG. 7 shows a specific example of configuration of signal processing circuitry according to the first modification of the first embodiment. In FIG. 7 , those configurations which are identical to their respective counterparts of FIG. 2 are indicated by the same reference numerals as in FIG. 2 and a description thereof is omitted. The electron microscope associated with the first modification is similar in configuration to the microscope shown in FIG. 1 and so its illustration and description is omitted.
[0105] The electron microscope associated with the first modification is similar to the configuration of the electron microscope 1 (see FIG. 2 ) associated with the first modification except that a filter 49 is inserted between the divider circuit 46 and the A/D converter 48 as shown in FIG. 7 .
[0106] The filter 49 has a narrow bandwidth of several kHz and can suppress noise generated in the divider circuit 46 (e.g., including log and antilog circuits). In the same way as in the above-described first embodiment, in the electron microscope associated with the present modification, the image signal detector 6 needing a bandwidth higher than several MHz and the noise detector 4 used in a bandwidth up to several MHz are separated from each other by analog circuitry and thus the image signal does not pass through the divider circuit 46 . For this reason, the filter having a narrow bandwidth for suppressing noise generated by the divider circuit 46 can be inserted. No limitation is imposed on the configuration of the filter 49 . Rather, any well-known filter circuit can be used.
[0107] The electron microscope associated with the first modification can yield advantageous effects similar to those produced by the electron microscope 1 associated with the first embodiment.
[0108] Furthermore, the electron microscope associated with the first modification can achieve noise cancellation giving rise to a still lower level of noise because the filter 49 can be inserted between the divider circuit 46 and the A/D converter 48 .
(2) Second Modification
[0109] A second modification is next described. FIG. 8 shows a specific example of configuration of signal processing circuitry in the second modification of the first embodiment. Those configurations of FIG. 8 which are identical to their respective counterparts of FIGS. 2 and 7 are indicated by the same reference numerals as in FIGS. 2 and 7 and a description thereof is omitted. The electron microscope associated with the second modification is identical in configuration to the microscope shown in FIG. 1 , and its illustration and description is omitted.
[0110] The electron microscope associated with the second modification is different from the configuration of the electron microscope 1 (see FIG. 2 ) associated with the first embodiment in that A/D converters 48 and 50 are incorporated in the arithmetic section 60 and that the arithmetic section 60 filters the output values of the A/D converter 48 by digital computations as shown in FIG. 8 . Consequently, in the second modification, noise generated by the divider circuit 46 can be suppressed by filtering operation of the arithmetic section 60 in the same manner as the above-described filter 49 (see FIG. 7 ) of the first modification.
[0111] The electron microscope associated with the second modification can yield advantageous effects similar to those produced by the electron microscope associated with the first modification.
(3) Third Modification
[0112] A third modification is next described. FIG. 9 shows a specific example of the configuration of signal processing circuitry in the third modification of the first embodiment. Those configurations of FIG. 9 which are identical to their respective counterparts of FIG. 2 are indicated by the same reference numerals as in FIG. 2 and a description thereof is omitted. The electron microscope associated with the third modification is identical in configuration to the microscope shown in FIG. 1 and thus its illustration and description is omitted.
[0113] The electron microscope associated with the third modification is similar to the configuration of the electron microscope 1 (see FIG. 2 ) associated with the first embodiment except that a constant Q is applied to the numerator input (X) of the divider circuit 46 instead of the output signal of the effective value computing circuit 44 as shown in FIG. 9 .
[0114] In the present modification, the noise detection circuit 40 is configured including amplifier 42 , divider circuit 46 , and A/D converter 48 .
[0115] The constant Q is applied to the numerator input (X) of the divider circuit 46 , and the output signal V 3 (see Eq. (3) above) of the amplifier 42 is applied, to the denominator input (Y). The divider circuit 46 performs a division of the former signal by the latter. Accordingly, the output signal V 4 of the divider circuit 46 is given by
[0000]
V
4
=
X
Y
=
Q
Gn
×
I
2
(
11
)
[0116] The output signal V 4 of the divider circuit 46 is converted from analog to digital form by the A/D converter 48 and applied to the arithmetic section 60 .
[0117] An offset is applied to the image signal by the preamplifier circuit 20 , and the resulting signal is amplified by amplifiers 24 and 32 to value (Gp×Ga×B). The arithmetic section 60 subtracts this value (Gp×Ga×B), i.e., a subtrahend, from the output value of the A/D converter 50 using a digital computation. The arithmetic section 60 performs a multiplication operation between the output value (Ga×Gp×S×I 1 ) of the image signal detector 6 from which brightness has been removed and the output value (Q/(Gn×I 2 )) of the A/D converter 48 using digital computations. The result of this multiplication operation is given by
[0000]
Ga
×
Gp
×
S
×
I
1
×
Q
Gn
×
I
2
=
Ga
×
Gp
×
S
×
n
×
Q
Gn
(
12
)
[0000] where I 1 =n×I 2 .
[0118] Note that none of the emission currents I 1 and I 2 containing emission noise are present in the right side of Eq. (12). Consequently, when the noise cancellation function is used, a value proportional to the brightness component S of the sample S to be imaged and observed is obtained in the same way as when there is no emission noise.
[0119] After performing the multiplication operation, the arithmetic section 60 operates to add the subtrahend (Ga×Gp×B) to the product of the multiplication (see Eq. (12) above) using a digital computation. The resulting sum is given by
[0000]
Ga
×
Gp
×
S
×
n
×
Q
Gn
+
Ga
×
Gp
×
B
=
Ga
×
Gp
×
(
S
×
n
×
Q
Gn
+
B
)
(
13
)
[0120] The arithmetic section 60 averages or otherwise arithmetically processes the sum (see Eq. (13) above) using digital computations to generate image data and sends the image data to the PC 2 shown in FIG. 1 .
[0121] In the electron microscope associated with the third modification, the image signal does not pass through the divider circuit 46 in the same way as in the electron microscope 1 associated with the first embodiment and so noise cancellation which results in a low level of noise and which can be implemented at high speed can be accomplished.
2. Second Embodiment
[0122] An electron microscope associated with a second embodiment of the present invention is next described by referring to FIG. 10 , which shows an example of configuration of this electron microscope. Those configurations of FIG. 10 which are identical to their respective counterparts of FIG. 1 are indicated by the same reference numerals as in FIG. 1 and a description thereof is omitted.
[0123] The electron microscope 1 associated with the second embodiment differs from the electron microscope 1 associated with the first embodiment in that the image detector 15 is replaced by a multi-segmented STEM detector 16 as shown in FIG. 10 .
[0124] The electron microscope 1 associated with the second embodiment has a plurality of distinct image signal detectors 6 corresponding to the detector segments of the multi-segmented STEM detector 16 . Each image signal detector 6 detects only electrons impinging on a certain detector area on the sensitive surface of the multi-segmented STEM detector 16 . This is equivalent to bringing the sensitive surface into coincidence with the diffraction plane in the electron microscope 1 so that electrons which are transmitted from the sample A into a certain solid angle region and scattered are detected. Therefore, the electron microscope 1 associated with the second embodiment can obtain information about the dependence of electrons scattered by the sample A on solid angle by the use of the multi-segmented STEM detector 16 .
[0125] FIG. 11 shows one example of configuration of the multi-segmented STEM detector 16 . This detector 16 is configured including a scintillator 602 , an optical fiber bundle 604 , and photomultiplier tubes (PMTs) 606 as shown in FIG. 11 .
[0126] The scintillator 602 has a sensitive surface 603 that is partitioned into a plurality of detector segments radially and in the direction of deflection. In the illustrated example, the sensitive surface 603 of the scintillator 602 has 16 detector segments. However, no limitation is placed on the number of the detector segments.
[0127] The optical fiber bundle 604 connects the detector segments of the scintillator 602 with the photomultiplier tubes 606 . Optical fibers making up the optical fiber bundle 604 transmit light outgoing from the detector segments of the scintillator 602 to respective ones of the photomultiplier tubes 606 .
[0128] The photomultiplier tubes 606 receive light emerging from the detector segments of the scintillator 602 via the optical fiber bundle 604 . The photomultiplier tubes 606 have a 1:1 correspondence with the detector segments of the scintillator 602 . The same number (16 in the illustrated example) of photomultiplier tubes 606 as the detector segments of the scintillator 602 are connected with the optical fiber bundle 604 .
[0129] FIG. 12 shows a specific example of configuration of the signal processing circuitry according to the second embodiment. Those configurations of FIG. 12 which are identical to their respective counterparts of FIG. 2 are indicated by the same reference numerals as in FIG. 2 and a description thereof is omitted.
[0130] As shown in FIG. 12 , there are as many image signal detectors 6 as the detector segments of the scintillator 602 . For example, in the present embodiment, 16 image signal detectors 6 are mounted in a corresponding manner to 16 detector segments of the scintillator 602 .
[0131] Each image signal detector 6 is configured including a respective one of the detector segments of the scintillator 602 , optical fiber for transmitting light emitted from this detector segment, a photomultiplier tube (PMT) 606 , a preamplifier circuit 20 , an amplifier circuit 30 , an A/D converter 50 .
[0132] In the present embodiment, in each image signal detector 6 , brightness B is added by an adder 22 to an image signal S×I 1 obtained from the photomultiplier tube 606 for which contrast has been adjusted, and then the signal is amplified by a factor of Gp by an amplifier 24 . The output signal V 1 (see Eq. (1) above) of the preamplifier circuit is amplified by a factor of Ga by the amplifier 32 . The output signal V 2 (see Eq. (2) above) of the amplifier 32 is converted from analog to digital form by the AID converter 50 and applied to the arithmetic section 60 .
[0133] In the present embodiment, the output values of the A/D converters 50 are applied from the image signal detectors 6 to the arithmetic section 60 . That is, in the illustrated example, the output values of the A/D converters 50 are applied from the 16 image signal detectors 6 to the arithmetic section 60 .
[0134] An offset is applied to each image signal by the respective preamplifier circuit 20 and the resulting signal is amplified by the amplifiers 24 and 32 to value (Gp×Ga×B). This value (Gp×Ga×B), i.e., a subtrahend, is subtracted from the output values of the A/D converters 50 by the arithmetic section 60 using digital computations. The arithmetic section 60 performs, using a digital computation, a multiplication operation between the output value (Ga×Gp×S×I 1 ) of the respective image signal detector 6 undergone the subtraction and the output value ((Gn×I 2 ) RMS /(Gn×I 2 )) of the A/D converter 48 . Then, the arithmetic section 60 adds the subtrahend (Ga×Gp×B) to the resulting products using digital computations. The arithmetic section 60 averages or otherwise arithmetically processes the sums (see Eq. (10) above) using digital computations to generate image data and sends the data to the PC 2 shown in FIG. 10 .
[0135] In this way, in the second embodiment, the arithmetic section 60 performs the above-described arithmetic operations in parallel in response to inputting of the output values of the A/D converters 50 of the image signal detectors 6 . For example, if the number of the detector segments of the scintillator 602 increases and the number of the image signal detectors 6 increases, and if the arithmetic section performs heavy duty arithmetic processing such as divisions, load may become so great that the parallel processing may not be carried out.
[0136] In the electron microscope associated with the second embodiment, a division is performed by the divider circuit 46 of the noise detector 4 and the arithmetic section 60 performs multiplication operations without performing a division operation, in the same way as in the first embodiment. Therefore, in the arithmetic section 60 , load incurred in processing the arithmetic operations on the output signals of the image signal detectors 6 can be reduced, for example, as compared with the case where division operations are performed on the output signals of the image signal detectors 6 . Consequently, in the electron microscope associated with the second embodiment, even if there are plural image signal detectors 6 , the load on the arithmetic section 60 can be reduced. In response to inputting of the output values of the A/D converters 50 of the plural image signal detectors 6 , the arithmetic section 60 can arithmetically process the output values in parallel and simultaneously.
3. Third Embodiment
[0137] An electron microscope associated with a third embodiment of the present invention is next described by referring to FIG. 13 , which shows one example of configuration of this electron microscope. Those configurations of FIG. 13 which are identical with their respective counterparts of FIG. 1 are indicated by the same reference numerals as in FIG. 1 and a description thereof is omitted.
[0138] The electron microscope 1 associated with the third embodiment is similar to the electron microscope 1 associated with the first embodiment except that it has a dark-field detector 17 and a bright-field detector 18 as shown in FIG. 13 .
[0139] The dark-field detector 17 has an annular scintillator, detects elastically scattered electrons scattered at large angles from the sample A, and outputs a dark-field image signal.
[0140] The bright-field detector 18 has a disk-like scintillator, detects electrons passed through a hole formed in the center of the dark-field detector 17 and scattering electrons, and outputs a bright-field image signal.
[0141] In the present embodiment, the bright-field detector 18 is disposed behind the dark-field detector 17 . Therefore, in the present embodiment, the dark-field image signal and the bright-field image signal can be simultaneously accepted.
[0142] In the present embodiment, there are two independent image signal detectors 6 a and 6 b corresponding to the two detectors 17 and 18 , respectively. Consequently, a bright-field image and a dark-field image can be observed simultaneously.
[0143] FIG. 14 shows one specific example of configuration of signal processing circuitry according to the third embodiment. Those configurations of FIG. 14 which are identical to their respective counterparts of FIG. 2 are indicated by the same reference numerals as in FIG. 2 and a description thereof is omitted.
[0144] As shown in FIG. 14 , the first image signal detector 6 a is configured including dark-field detector 17 , preamplifier circuit 20 , amplifier circuit 30 , and A/D converter 50 .
[0145] In the first image signal detector 6 a, a dark-field image signal S×I 1 for which brightness has been adjusted is obtained from the dark-field detector 17 . Brightness B is added to this signal by the adder 22 . Then, the resulting signal is amplified by a factor of Gp by the amplifier 24 . The output signal V 1 (see Eq. (1) above) of the preamplifier circuit is amplified by a factor of Ga by the amplifier 32 . The output signal V 2 (see Eq. (2) above) of the amplifier 32 is converted from analog to digital form by the A/D converter 50 and applied to the arithmetic section 60 .
[0146] The second image signal detector 6 b is configured including bright-field detector 18 , preamplifier circuit 20 , amplifier circuit 30 , and A/D converter 50 .
[0147] In the second image signal detector 6 b, a bright-field image signal S×I 1 for which contrast has been adjusted is obtained from the bright-field detector 18 , in the same way as in the first image signal detector 6 a. Brightness B is added to this signal by the adder 22 . The resulting signal is amplified by a factor of Gp by the amplifier 24 . The output signal V 1 (see Eq. (1) above) of the preamplifier circuit is amplified by a factor of Ga by the amplifier 32 . The output signal V 2 (see Eq. (2) above) of the amplifier 32 is converted from analog to digital form by the A/D converter 50 and impressed on the arithmetic section 60 .
[0148] In the first image signal detector 6 a, an offset is applied to the image signal by the preamplifier circuit 20 , and the resulting signal is amplified to value (Gp×Ga×B) by the amplifiers 24 and 30 . The arithmetic section 60 subtracts this value (Gp×Ga×B), i.e., a subtrahend, from the output value of the A/D converter 50 of the first image signal detector 6 a, using a digital computation. The arithmetic section 60 then performs, using a digital computation, a multiplication operation between the output value (Ga×Gp×S×I 1 ) of the first image signal detector 6 a from which brightness has been removed and the output value ((Gn×I 2 ) RMS /(Gn×I 2 )) of the A/D converter 48 . Then, the arithmetic section 60 adds the subtrahend (Ga×Gp×B) to the resulting product using a digital computation. The arithmetic section 60 averages or otherwise arithmetically processes the sum (see Eq. (10) above) using a digital computation to generate image data and sends the data to the PC 2 shown in FIG. 13 . The PC 2 receives the image data generated by the arithmetic section 60 , displays a dark-field image of the sample A from which emission noise has been removed or reduced on a display unit, stores the image, and otherwise processes it.
[0149] The arithmetic section 60 performs the above-described processing also on the output value of the A/D converter 50 of the second image signal detector 6 b. The PC 2 displays the bright-field image of the sample A whose emission noise has been removed or reduced on the display unit, stores the image, and otherwise processes it.
[0150] In the arithmetic section 60 , the arithmetic operation on the output value of the A/D converter 50 of the first image signal detector 6 a and the arithmetic operation on the output value of the A/D converter 50 of the second image signal detector 6 b are carried out in parallel and simultaneously.
[0151] The electron microscope associated with the third embodiment can yield advantageous effects similar to those produced by the electron microscope associated with the second embodiment.
4. Other Embodiments
[0152] It is to be understood that the present invention is not restricted to the foregoing embodiments but rather can be practiced in variously modified forms without departing from the gist and scope of the present invention.
[0153] For example, in the electron microscope 1 associated with the first embodiment, as shown in FIG. 2 , the output signal of the effective value computing circuit 44 is divided in an analog manner by the output signal of the amplifier 42 by means of the divider circuit 46 in the noise detector 4 . In the electron microscope associated with the third modification of the first embodiment, as shown in FIG. 9 , the constant Q is divided in an analog manner by the output signal of the amplifier 42 by means of the divider circuit 46 in the noise detector 4 . In the electron microscope associated with the present invention, the dividend of the divider circuit 46 is not restricted to the above-described effective value of a noise signal or a constant. The dividend may be set to an average value of a noise signal or other value. Even in this case, according to the electron microscope associated with the present invention, noise cancellation which results in a low level of noise and which can be implemented at high speed can be accomplished in the same way as in the above embodiments.
[0154] Furthermore, in the above-described example of the electron microscope 1 associated with the first embodiment, analog circuitry configured including log and antilog circuits is described as the divider circuit 46 as shown in FIG. 2 . In the electron microscope associated with the present invention, a general-purpose IC, for example, is used as the divider circuit 46 . That is, the noise detector 4 may divide the output signal of the effective value computing circuit 44 by the output signal of the amplifier 42 using a digital arithmetic operation. Similarly, in the above-described example of the electron microscope associated with the third modification of the first embodiment, an analog circuit is used as the divider circuit 46 as shown in FIG. 9 . The noise detector 4 may divide the constant Q by the output signal of the amplifier 42 using a digital arithmetic operation. Even in this case, according to the electron microscope associated with the present invention, the image signal does not undergo any division operation using a digital arithmetic operation. Hence, noise cancellation which results in a low level of noise and which can be implemented at high speed can be accomplished in the same way as in the foregoing embodiments.
[0155] In electron microscopes associated with the above-described embodiments, an offset is added to an image signal by the preamplifier circuit 20 for brightness adjustment as shown in FIG. 2 and a value equivalent to the offset is subtracted in the arithmetic section 60 prior to a multiplication, and the value which is equivalent to the offset and which was used as a subtrahend is added to the product. In the electron microscope associated with the present invention, no offset may be added in the preamplifier circuit 20 . A multiplication may be performed in the arithmetic section 60 . After this multiplication, i.e., after performing a noise canceling process, an offset for brightness adjustment may be added. Also, in this case, advantageous effects similar to those produced by the above embodiments can be obtained.
[0156] In the description of the above embodiments, a scanning transmission electron microscope (STEM) is taken as an example of electron microscope. The present invention can also be applied to other type of electron microscope such as a scanning electron microscope (SEM). Also, in this case, advantageous effects similar to those produced by the above embodiments can be had.
[0157] It is to be noted that the above-described embodiments and modifications are merely exemplary and that the invention is not restricted thereto. For example, such embodiments and modifications may be appropriately combined.
[0158] The present invention embraces configurations (e.g., configurations identical in function, method, and results or identical in purpose and advantageous effects) which are substantially identical to the configurations described in any one of the above embodiments. Furthermore, the invention embraces configurations which are similar to the configurations described in any one of the above embodiments except that their nonessential portions have been replaced. Additionally, the invention embraces configurations which are identical in advantageous effects to, or which can achieve the same object as, the configurations described in any one of the above embodiments. Further, the invention embraces configurations which are similar to the configurations described in any one of the above embodiments except that a well-known technique is added.
[0159] Having thus described my invention with the detail and particularity required by the Patent Laws, what is desired protected by Letters Patent is set forth in the following claims. | An electron microscope is offered that is capable of achieving noise cancellation which results in a low level of noise and which can be implemented at high speed. An electron microscope ( 1 ) associated with the present invention includes: an electron beam source ( 11 ) for producing an electron beam; a noise detector ( 4 ) for detecting a part of the beam to thereby produce a beam detection signal and dividing a dividend by the beam detection signal; at least one image signal detector ( 6 ) for detecting an image signal obtained by making the beam impinge on a sample (A); and an arithmetic section ( 60 ) for performing a multiplication between an output signal of the image signal detector ( 6 ) and an output signal of the noise detector ( 4 ). | 84,130 |
FIELD OF THE INVENTION
[0001] The present invention relates to two wheeler stands. In particular, this invention relates to a device for providing improved safety in using a side stand for parking the two wheeled vehicle.
BACKGROUND OF THE INVENTION
[0002] Support stands are typically used to position a two wheeled vehicle in stationary position when not being driven by a rider. These stands have to be pushed open or extended from a closed inactive position to an open active position adapted to support the weight of the vehicle in a parked state. There are two types of stands commonly used to park a two wheeler. One of these stands is a side stand and the other is a centre stand. Both are provided between the wheel centers. To park a two wheeler using a stand, the support unit of the stand has to be swiveled to an open position and the vehicle pulled backwards or tilted to one side to achieve a parked stationary position.
[0003] The centre stand of a two wheeler keeps the vehicles while parked, in plane normal to the ground level as compared to a slightly tilted position achieved while using a side stand. Both these stands are provided with stoppers to limit the movement of the stand with reference to the vehicle frame. A typical side stand for a two wheeler consists of bracket fastened to the frame of the vehicle, between the front wheel and rear wheels. The bracket is provided with a pivoted joint consisting of a swiveling support leg assembly. A spring is used to keep the leg assembly in a substantially horizontal position raised and away from the ground level, to prevent the stand from accidentally opening whilst the vehicle is in motion. Starting and riding a two wheeler with the side stand in a deployed state can lead to accidents and injuries to the rider and also to the bystanders.
[0004] Various attempts have been made to alert the rider about the deployed state of the side stand support either by preventing engine start or alarms.
[0005] U.S. Pat. No. 4,016,538 discloses a “Safety device for a motorcycle”. This device actuates the horn of a motorcycle if the side stand is down, the ignition is on, and the motorcycle is in the driving position using a mercury contact switch which is activated by the tilted position of the motor cycle when parked using a side stand and another switch mechanically connected to the stand. The horn is activated when the driver turns the ignition and brings the motor cycle to a substantially vertical position without putting up the side stand. The use of contact type switches and mercury filled position switch, acting in unison, to activate a sound alarm, is subject to wear and tear due to physical contact, electrical arcing, leakage of mercury and abrasion due to inclusion of dust particles.
[0006] U.S. Pat. No. 6,733,025 discloses a “Motorcycle stand control mechanism”. This is a motorcycle stand control device having a rotor adapted to rotate when the wheels of the motorcycle is rotating. The rotor is provided with a set of magnets alternatively arranged around the periphery of the rotor and a circuit board having sensor adapted to act with the magnets and to output a corresponding control signal to turn the motorcycle stand of the motorcycle subject to the status of the rotary driven member. This device consists of many mechanical components like rotating wire positioned in a flexible cable to transmit the drive, direct current motor and gear drive to retract the side stand leg support. All these components are subject to high degree of mechanical wear and tear and the components that are exposed to the road surface and are likely to be damaged in inclement weather conditions and also not suitable for rough and rocky terrains.
[0007] U.S. Pat. No. 6,918,607 discloses a “Side stand device”. This device consists of a rotary switch which attempts to prevent transmission of vibrations from a body frame to a rotary switch to reliably maintaining the function and performance of the rotary switch. The rotary switch is provided in coaxial relationship with the side stand through a pivot bolt and a securing bolt. A sheet is interposed between the rotary switch and the pivot bolt, and a tube and a sheet are interposed between the rotary switch and the securing bolt. The sheets and the tube are formed from rubber members. A cushion member is interposed between an engaging member of an inner rotor in the rotary switch and a locking hole of the side stand. The cushion member is formed from a rubber member. The cushioning members and the contacts of the rotary switch are subject to wear and tear and are likely to be damaged in regular use and have to be replaced during periodic maintenance.
[0008] U.S. Pat. No. 7,631,885 discloses an “Intelligent interlock for a motorcycle stand”. This device consists of a side stand movable between an extended position in which the stand supports the motorcycle and a retracted position. The motorcycle includes a sensor to generate a signal to indicate the extended or retracted position of the side stand; a gear position sensor to generate signal about the neutral state or the non-neutral state of the transmission gears; a vehicle speed sensor to detect the speed of the motorcycle and a controller programmed for monitoring of the stand signal and for preventing operation of the engine when one of the gear position sensor and the vehicle speed sensor fails to communicate successfully with the controller, preventing operation of the engine being dependent upon the stand signal and an output of the other of the gear position sensor and the vehicle speed sensor. The stand position sensor is a Hall-effect sensor mounted externally and operates to sense the presence of the side stand in the retracted position by sensing a magnet or ferrous material of the side stand. The use of three different sensors and external mounting of the stand position sensor are likely to be damaged in inclement weather conditions, presence of magnets or ferrous particles and are also not suitable for rough and rocky terrains.
[0009] Thus, there is a need for a device that warns the rider about the deployed condition of the side stand before he starts to ride the vehicle and which overcomes the problems hitherto encountered in a two wheeler having a side stand arrangement.
OBJECTS OF THE PRESENT INVENTION
[0010] An object of this invention is to provide a device that improves safety in using a side stand for parking the two wheeled vehicle.
[0011] Still another object of this invention is to provide a safety device that positively indicates the deployment of the side stand of a two wheeler.
[0012] Yet another object of this invention is to provide a safety device that is adapted to function even in adverse atmospheric conditions and in inclement weather.
[0013] Yet another object of this invention is to provide a safety device that is free from wear and tear of the components and adapted to function accurately repeatedly.
[0014] Yet another object of this invention is to provide a safety device that can function even at high ambient temperatures.
[0015] Yet another object of this invention is to provide a safety device that is easy to install.
[0016] Yet another object of this invention is to provide a safety device that does not require periodic servicing or maintenance to be carried out.
BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS
[0017] All aspects and advantages of the present invention will become apparent with the description of the preferred non limiting embodiment, when read together with the accompanying drawings, in which:
[0018] FIG. 1 is the three dimensional view of the side stand of a two wheeler provided with the safety device in accordance with this invention, depicted in an operative position of the side stand;
[0019] FIG. 2 is the exploded view of the side stand of a two wheeler provided with the safety device in accordance with this invention, as shown in FIG. 1 ;
[0020] FIGS. 3 and 4 are the elevation and side elevation of the side stand of a two wheeler provided with the safety device in accordance with this invention, as shown in FIG. 1 , depicted in an operative position of the side stand;
[0021] FIG. 5 is the sectional view of the side stand of a two wheeler provided with the safety device in accordance with this invention, as shown in FIG. 3 , depicted in an operative position of the side stand;
[0022] FIGS. 6 and 7 are the elevation and side elevation of the side stand of a two wheeler provided with the safety device in accordance with this invention, as shown in FIG. 1 , depicted in an inoperative position of the side stand;
[0023] FIG. 8 is the sectional view of the side stand of a two wheeler provided with the safety device in accordance with this invention, as shown in FIG. 6 , depicted in an inoperative position of the side stand;
[0024] FIGS. 9 and 10 are the elevation and the end view of the base plate of the safety device in accordance with this invention as shown in FIG. 1 ;
[0025] FIG. 11 is the three dimensional view of the housing of the safety device in accordance with this invention as shown in FIG. 1 ;
[0026] FIGS. 12 and 13 are the elevation and sectional view of the plate holder of the safety device in accordance with this invention as shown in FIG. 1 ;
[0027] FIGS. 14 and 15 are the plan and elevation of the fastener of the safety device in accordance with this invention as shown in FIG. 1 ;
[0028] FIGS. 16 and 17 are elevation and end view of the printed circuit board of the safety device in accordance with this invention as shown in FIG. 1 ; and
[0029] FIG. 18 is the functional diagram of the programmable mixed signal CMOS technology Hall-effect sensor used in the safety device in accordance with this invention as shown in FIG. 1 .
SUMMARY OF THE INVENTION
[0030] According to this invention there is provided a safety device for a side stand mounted on a two wheeled vehicle, said device comprising:
[0031] a base plate adapted to be fastened to the frame of the two wheeler between the wheels centers, said base plate provided with specific peripheral cut out having two edges defining an included angle “X” between said edges; a holding member defining a first surface, an integral coaxial annular disc, a circular cavity and an arcuate cut out; said holding member pivot-ably mounted on the base plate; a move-able element rigidly mounted on said first surface of the holding member; a housing comprising a circular disc having an integral circular side wall defining a cavity provided with a central cylindrical projection normal to the circular disc; said central cylindrical projection defining at least three cylindrical locating regions; said circular disc provided with at least two spaced apart locating pins; said housing removably fastened to the base plate; an integrated circuit unit comprising a sensor unit, resistors-capacitors and pad connector points; said integrated circuit unit provided at least two mounting locations; in an assembled configuration the integrated circuit unit adapted to mount in said housing so as maintain specific orientation and locational accuracy with reference to the first locating region, mounting locations and said locating pins; a support element pivot ably mounted on said base plate; said support element adapted to swivel from an inoperative closed position to an operative open position within the included angle “X” of edges and; a fastener element provided with a central cylindrical cavity adapted to pivot-ably fasten said holding member with reference to the base plate; in an assembled configuration the circular cavity of the holding member adapted to receive the one end of the fastener and the central cylindrical cavity adapted to locate the third locating region of the housing so as to maintain specific orientation and locational accuracy of said move-able member with reference to the sensor unit in a first inoperative swiveled close position and an operative swiveled open position of the of the support element.
[0032] Typically the included angle “X” is preferably more than 90 degrees but less than 125 degrees.
[0033] Typically the move able element is a permanent magnet selected from a group of permanent magnets consisting of Alnico, Samarium-Cobalt, Neodymium-Iron-Boron magnets.
[0034] Typically the integrated circuit unit is mounted on a rigid polymer base and covered with protective coating.
[0035] Typically the sensor unit is a programmable digital Hall effect sensor.
[0036] Typically the safety device of this invention is adapted to be retrofitted to a two wheeled vehicle.
DESCRIPTION OF THE INVENTION
[0037] The present invention relates to a safety device for the side stand of a two wheeler which overcomes the limitations hitherto encountered in existing devices employed for preventing accidents and injuries in using the side stand of the two wheeler.
[0038] Referring FIG. 1 , the safety device for the side stand of a two wheeler in accordance with this invention is indicated generally by the reference numeral 100 . The safety device for the side stand of a two wheeler ( 100 ) comprises a base plate ( 1 ) adapted to be fastened to the frame (not specifically shown) of the two wheeler between the wheels centers. The base plate ( 1 ) is provided with a pivot able support element ( 6 ). A housing ( 4 ) is provided to secure the components of the safety device ( 100 ).
[0039] FIG. 2 is the exploded view of the safety device for the side stand of a two wheeler ( 100 ) comprising base plate ( 1 ); a holding member ( 2 ); a move-able element ( 3 ); a housing ( 4 ); an integrated circuit unit ( 5 ); a support element ( 6 ); and a fastener element ( 7 ). The holding member ( 2 ) and the support element ( 6 ) are pivot ably secured to base plate ( 1 ) by the fastener element ( 7 ). The move-able element ( 3 ) is rigidly secured to the holding member ( 2 ). The integrated circuit unit ( 5 ) positioned within the housing ( 4 ). The housing ( 4 ) is removably fastened to the base plate ( 1 ) of the safety device for the side stand of a two wheeler ( 100 ).
[0040] Referring to FIGS. 3 and 4 the safety device for the side stand of a two wheeler ( 100 ) is in an operative swiveled open position of the support element ( 6 ). In this operative condition (refer FIG. 5 ) the move-able element ( 3 ) positioned in close proximity of the integrated circuit unit ( 5 ). A sensor (not specifically shown in this view) embedded in the integrated circuit unit ( 5 ) is adapted to sense the relative position of the move-able element ( 3 ) and generate an output signal to indicate of the operative swiveled open position of the support element ( 6 ).
[0041] Referring to FIGS. 6 and 7 the safety device for the side stand of a two wheeler ( 100 ) is in an inoperative swiveled close position of the support element ( 6 ). In this inoperative condition (refer FIG. 8 ) the move-able element ( 3 ) is positioned angularly displaced to be relatively away from the integrated circuit unit ( 5 ). The sensor (not specifically shown in this view) embedded in the integrated circuit unit ( 5 ) is adapted to sense the relative position of the move-able element ( 3 ) and generate an output signal to indicate of the inoperative swiveled closed position of the support element ( 6 ).
[0042] Referring to FIGS. 9 and 10 the base plate ( 1 ) of the safety device for the side stand of a two wheeler ( 100 ) is provided with circular opening ( 15 ) adapted to receive the fastener element ( 7 ) (not specifically shown). The base plate ( 1 ) is also provided with specific peripheral cut out having two edges ( 17 ) and ( 19 ) defining an included angle “X” between said edges.
[0043] In an assembled operative condition of the safety device for the side stand of a two wheeler ( 100 ) the fastener element ( 7 ), the holding member ( 2 ) and the support element ( 6 ) (not specifically shown in these figures) are adapted to be angularly displaced with reference to the centre of said circular opening ( 15 ). Said displacement limited within the included angle “X” defined by edges ( 17 ) and ( 19 ).
[0044] Referring to FIG. 11 the housing ( 4 ) of the side stand of a two wheeler ( 100 ) comprises of a circular disc ( 25 ) provided with an integral circular side wall ( 27 ) so as to define a cavity provided with a central cylindrical projection ( 31 ) normal to the circular disc ( 25 ). The central cylindrical projection ( 31 ) defining three cylindrical locating regions ( 33 ) ( 35 ) and ( 37 ) having different diameters. In an assembled operative condition of the safety device for the side stand of a two wheeler ( 100 ) the cylindrical locating regions ( 33 ) ( 35 ) and ( 37 ) are adapted to locate and position the integrated circuit unit ( 5 ), the holding member ( 2 ) and the fastener element ( 7 ) respectively, so as to maintain concentricity and air gap of the assembled components in an inoperative swiveled closed position and in an operative swiveled open position of the support element ( 6 ). Two spaced apart locating pins ( 39 ) provided on the circular disc ( 25 ) are adapted to locate the integrated circuit unit ( 5 ). The circular side wall ( 27 ) is provided with an ingress opening ( 41 ) for cable harness connection to the integrated circuit unit ( 5 ).
[0045] Referring to FIGS. 12 and 13 the holding member ( 2 ) of the safety device for the side stand of a two wheeler ( 100 ) is an arcuate member provided with a circular opening defining a first surface ( 45 ) provided with an integral coaxial annular disc ( 47 ) adapted to engage and coaxially locate the holding member ( 2 ) in the cylindrical locating region ( 35 ) of the cylindrical projection ( 31 ) provided on the housing ( 4 ) of the safety device for the side stand of a two wheeler ( 100 ). The holding member ( 2 ) further defining a circular cavity ( 49 ) adapted to coaxially locate the a fastener element ( 7 ) and an arcuate cut out ( 51 ) adapted to locate the support element ( 6 ).
[0046] Referring to FIGS. 14 and 15 the fastener element ( 7 ) is provided with an hexagonal profile ( 55 ) at one end of a cylindrical surface ( 57 ) and adjoining threaded end ( 59 ). The fastener element ( 7 ) is also provided with a central cylindrical cavity ( 61 ) at the hexagonal end. In an assembled configuration of the safety device for the side stand of a two wheeler ( 100 ) the cylindrical cavity ( 61 ) is adapted to receive the cylindrical locating region ( 37 ) of the cylindrical projection ( 31 ) provided on the housing ( 4 ).
[0047] Referring to FIGS. 16 and 17 the integrated circuit unit ( 5 ) is a substantially semicircular disc having a central cutout. the components of the integrated circuit unit ( 5 ) include a sensor unit ( 65 ) resistors and capacitors ( 69 ) and pad connector points ( 67 ) for conducting the signal generated by the sensor unit ( 65 ) to a controller unit (not included in this invention) adapted to read the signal received and generate audio or visual alerts and prevent engine start of the two wheeler engine. The integrated circuit unit ( 5 ) is also provided two mounting location holes ( 71 ) complementary to the spaced apart locating pins ( 39 ) provided on the circular disc ( 25 ) of the housing ( 4 ). These mounting location holes ( 71 ) accurately locate the integrated circuit unit ( 5 ) within the housing ( 4 ), maintaining the relative angular location of the sensor unit ( 65 ) with reference to the move-able element which is rigidly secured to the holding member ( 2 ). The printed circuit board is mounted on a rigid polymer base ( 73 ) and covered with protective coating ( 75 ) The cylindrical locating regions ( 33 ) ( 35 ) provided on the central cylindrical projection ( 31 ) of the housing ( 4 ) locate and maintain the positional accuracy and the air gap between the sensor unit ( 65 ) and the move-able element ( 3 ).
[0048] The sensor unit ( 65 ) typically is a complementary metal oxide semiconductor (CMOS) Hall sensor having facility to switch the direction of current through the Hall elements thereby eliminating the offset errors typical of semiconductor Hall elements. Other features like preset-able functional characteristics like gain, offset, temperature coefficient of gain (to compensate different magnetic materials thermal dependencies) provides programmable algorithms for complex signal processing in real time.
[0049] In this invention a change in the magnetic flux intensity causes a protected, magnetically biased pre-programmed sensor to go in a precise switch mode. The switching and hysteresis is controlled by the profile of a ferrous strip positioned accurately with controlled air gap between the face of the ferrous strip face and the sensing location of the sensor. A Complementary metal-oxide-semiconductor (CMOS) type Hall effect sensor was used. The Hall effect switch was mounted on a sturdy printed circuit board having a bias magnet, short circuit, reverse polarity protection and with a metal-oxide-semiconductor field-effect transistor (MOSFET) for output indication. The sensor used has wide operational parameters, with an operating voltage range of 2.7V to 24V, a magnetic latch range of ±0.4 mT to ±80 mT and a magnetic switch range of ±1.5 mT to ±66 mT and a programmable hysteresis range between 1 mT and 36 mT. The negative thermal coefficient can be adjusted in the range of 0 to −2000 ppm/° C. to match all currently available permanent magnet materials or to use with electromagnet (current sensing) actuation. This device has an operational temperature range spanning −40° C. to +150° C., making it highly suited for use in demanding automotive or industrial environments.
[0050] The Hall effect sensor used for testing the invention was a “Melexis” programmable unit. Referring to FIG. 18 the functional diagram of the programmable Hall-effect sensor provided with mixed signal CMOS technology, includes a voltage regulator, Hall sensor with advanced offset cancellation system and an open-drain output driver, all provided in a single package. The sensor is provided with built-in reverse voltage protection therefore a serial resistor or diode on the supply line is not required and the sensor function effectively at low voltage operation down to 2.7V while being reverse voltage tolerant. In the event of a drop below the minimum supply voltage during operation, the under-voltage lock-out protection will automatically freeze the device, preventing the electrical perturbation to affect the magnetic measurement circuitry. The open drain output is fully protected against short-circuit with a built-in current limit. An additional automatic output shut-off is activated in case of a prolonged short-circuit condition. A self-check is then periodically performed to switch back to normal operation if the short-circuit condition is released. The on-chip thermal protection also switches off the output if the junction temperature increases above an abnormally high threshold. It will automatically recover once the temperature decreases below a safe value.
[0051] The advantages of this invention includes:
[0052] 1. There are no wear and tear of the components used in the device as the sensing the position of the side stand and generating appropriate signal is fully contact less. This ensures error free sensing in more than one million repetitions.
[0053] 2. The components of the device are fully enclosed in a dust and weather proof housing ensuring maintenance free operation.
[0054] 3. The extent of angular displacement and locational accuracy is controlled by the complementing projections and openings provided in the housing.
[0055] 4. The air gap between the moveable and the fixed components within their entire range of angular displacement is constant. This ensures non varying signal generation repeatedly.
[0056] 5. This device may be fitted on varying models and types of two wheelers as modification is required only in the base plate that is used for mechanical fitment. Within the same model or type of two wheeler the variations of vehicle body part and side stand does not adversely affect on the switching performance. This makes the fitment of the unit to the vehicle easy requiring low skill levels.
[0057] 6. As the sensor unit is pre-programmable, over a wide range of design variables as required for different models and types of two wheelers, the inventory cost in manufacturing is reduced considerably and the device is highly suitable of for just-in-time inventory management practice at the vehicle assembly line.
[0058] While considerable emphasis has been placed herein on the particular features of “a device for providing improved safety in using a side stand for parking the two wheeled vehicle” and the improvisation with regards to it, it will be appreciated that various modifications can be made, and that many changes can be made in the preferred embodiment without departing from the principles of the invention. These and other modifications in the nature of the invention or the preferred embodiments will be apparent to those skilled in the art from the disclosure herein, whereby it is. to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation. | A device adapted for accurate and quick assembly on a two wheeled vehicle for enhanced safety in using a side stand for parking of the vehicle is disclosed. | 26,283 |
This is a divisional of co-pending application Ser. No. 07/188,985, filed on Apr. 29, 1988, now U.S. Pat. No. 5,138,055, which is a continuation of application Ser. No. 06/864,622 filed May 16, 1986, now U.S. Pat. No. 4,742,118.
The present invention relates to new and improved urethane-functional amino-s-triazine crosslinking agents, to curable compositions incorporating them and to methods of making and using the new and improved crosslinkers. More particularly, it relates to novel s-triazine compounds containing at least one N,N-bis(alkoxy- or hydroxyalkoxy-carbonylamino C 2 -C 10 alkyl)amino substituent. The novel urethane functional s-triazine crosslinking agents are useful for crosslinking active-hydrogen materials to form cured products characterized by excellent toughness, hardness and flexibility. They are especially useful for providing curable light-stable coatings for articles intended for outdoor use.
BACKGROUND OF THE INVENTION
Crosslinking agents comprising s-triazine compounds are known in the art. Koral et al., U.S. Pat. No. 3,661,819, for example, disclose a family of s-triazine curing agents comprising fully or partially alkylated melamine-formaldehyde compounds having the formula: ##STR1## or (ii) a benzoguanamine compound of the formula: ##STR2## wherein R is hydrogen or alkyl of from 1 to 12 carbon atoms. It is also known to use oligomers of such compounds, which are low molecular weight condensation products containing for example two, three or four triazine rings, joined by --CH 2 OCH 2 -- linkages, as well as mixtures of any of the foregoing. These are used to self-condense or used to cure active hydrogen-containing materials, especially polymers which contain carboxyl groups, alcoholic hydroxy groups, amide groups and groups convertible to such groups, such as methylol groups. Coatings containing melamine-formaldehyde crosslinkers have good hardness and high crosslink density. The coatings generally do not discolor upon exposure to light, especially ultraviolet from sunlight or other sources, moisture or oxygen. A serious shortcoming of these cross-linkers is that they tend to liberate formaldehyde on curing which is objectionable to both formulators and end-users. Moreover, coatings crosslinked with these materials have a tendency to brittleness, at least as compared with other coatings such as polyurethane coatings.
Crosslinking agents based on beta-hydroxyalkyl carbamates are known from Valko, U.S. Pat. No. 4,435,559. Valko describes curable compositions comprising a bis(beta hydroxyalkyl carbamate) crosslinker, an active-hydrogen material and a cure catalyst. The Valko crosslinkers are prepared from diisocyanate intermediates. The coatings derived from aromatic blocked diisocyanates are not light stable in outdoor use. Although coatings prepared therefrom are more flexible than the aforementioned melamine-formaldehyde based coatings, they suffer from poor cross-link density, poor hardness and poor organic solvent resistance. Moreover, they require use and handling of hazardous and toxic isocyanate materials.
Another patent dealing with beta-hydroxyalkyl carbamate crosslinkers is Jacobs, III, Parekh and Blank, U.S. Pat. No. 4,484,994, which discloses their use in cathodically electrodepositable coating compositions.
Accordingly, to overcome certain drawbacks of the prior art crosslinkers, it is an object of the present invention to provide new and improved crosslinking agents for use with active hydrogen containing materials and polymers which impart the hardness, toughness, solvent resistance and light stability of melamine-formaldehyde crosslinkers but without the brittleness, and which possess the abrasion resistance and flexibility of polyurethane coatings.
It is another object of the present invention to provide melamine-urethane crosslinkers for curable systems which are formaldehyde and isocyanate free.
It is a further object of the present invention to provide curable coating compositions for use in powder coating, electrocoating and solvent-borne coating applications.
SUMMARY OF THE INVENTION
In accordance with these and other objects, the present invention provides new and improved urethane-functional s-triazine crosslinking agents comprising:
(i) a compound of the formula ##STR3## wherein R 1 is ##STR4## wherein A 1 and A 2 are, independently, straight or branched chain divalent alkylene of from about 2 to about 10 carbon atoms and Q 1 and Q 2 are, independently straight or branched chain alkyl or alkoxyalkyl of from about 1 to about 20 carbon atoms or straight or branched chain beta-hydroxyalky of from about 2 to about 10 carbon atoms; R 2 and R 3 are, independently, the same as R 1 and, in addition, Cl, Br, I, OR 4 , --NHR 5 , --NR 5 R 6 , ##STR5## and R 4 , R 5 , R 6 are, independently, a monovalent- and R 7 is a divalent aliphatic, cycloaliphatic, aromatic or alkylaromatic radial, which can contain heteroatoms such as O, N, S or P, either in the chain or as side substituents and R 8 and R 9 are the same as R 4 , R 5 and R 6 and, in addition, hydrogen or, when R 7 , R 8 and R 9 are taken together, divalent heterocyclic incorporating the nitrogens to which they are attached;
(ii) a self-condensed oligomer of (i);
(iii) a urethane or urea compound comprising the reaction product of (i) or (ii) with a mono- or polyol or a mono- or polyamine; or
(iv) a mixture of any of the foregoing.
With respect to compound (i) A 1 and A 2 are preferably C 2 -C 6 alkyl and Q 1 and Q 2 are beta-hydroxyethyl, beta-hydroxy propyl, e.g., a mixture of beta-hydroxy-alpha-methylethyl and beta-hydroxy-beta-methylethyl, or a mixture of beta-hydroxypropyl and butyl or octyl. Also preferred are oligomers of (i) in which A 1 and A 2 are ethylene and Q 1 and Q 2 are beta-hydroxyethyl or beta-hydroxypropyl, as well as triazines in which R 2 and R 3 are the same as R 1 .
Also contemplated by the present invention are thermosettable compositions comprising:
(a) a cross-linking agent comprising:
(i) a triazine compound selected from a compound of the formula: ##STR6## wherein R 1 is ##STR7## wherein A 1 and A 2 are, independently, straight or branched chain divalent alkylene of from about 2 to about 10 carbon atoms and Q 1 and Q 2 are, independently straight or branched chain alkyl or alkoxyalkyl of from about 1 to about 20 carbon atoms or straight or branched chain beta-hydroxyalky of from about 2 to about 10 carbon atoms; R 2 and R 3 are, independently, the same as R 1 and, in addition, Cl, Br, I, OR 4 , --NHR 5 , --NR 5 R 6 , ##STR8## and R 4 , R 5 , R 6 are, independently, a monovalent- and R 7 is a divalent aliphatic, cycloaliphatic, aromatic or alkylaromatic radical, which can contain heteroatoms such as O, N, S or P, either in the chain or as side substituents and R 8 and R 9 are the same as R 4 , R 5 and R 6 and, in addition, hydrogen or, when R 7 , R 8 and R 9 are taken together, divalent heterocyclic incorporating the nitrogens to which they are attached;
(ii) a self-condensed oligomer of (i);
(iii) a urethane or urea compound comprising the reaction product of (i) or (ii) with a mono- or polyol or a mono- or polyamine; or
(iv) a mixture of any of the foregoing, and, optionally,
(b) a polymer containing two or more active hydrogen functional groups; and
(c) optionally, a cross-linking catalyst; the cross-linking agent (a) and the polymer (b) being stable relative to each other in the composition at ambient temperature and reactive with each other at elevated temperature.
In preferred features of this aspect of the invention, the material (b) contains at least two reactive carboxyl, alcoholic hydroxy or amide groups, or a mixture of such groups, preferably a hydroxy-functional acrylic resin, a polyester polyol or a polyether polyol. Preferably the triazine will be as set forth specifically above, and the cure catalyst, if used, will be a metalorganic compound or quaternary salt, as set forth hereinafter.
Alternatively, the urethane-functional s-triazine compounds of the above formulae can be used as
(a) a self-crosslinkable material, alone, or
(b) with an optional catalyst in providing protective and/or decorative coatings and binders.
Also provided by the invention are articles of manufacture comprising substrates protectively coated with a baked and cured composition as defined above.
Also in accordance with this invention there is provided a novel process for the preparation of a triazine compound of the formula ##STR9## wherein R a 1 is ##STR10## wherein A 1 and A 2 are, independently, straight or branched chain divalent alkylene of from about 2 to about 10 carbon atoms and Q a 1 and Q b 2 are, independently, straight or branched chain beta-hydroxyalkyl of from about 2 to about 10 carbon atoms; R 2 and R 3 are, independently, the same as R a 1 and, in addition, Cl, Br, I or OR a 4 , wherein R a 4 is monovalent aliphatic of from about 1 to about 6 carbon atoms, said process comprising reacting a compound of the formula ##STR11## with a compound of the formula ##STR12## wherein at least one of X, Y and Z are displaceable groups selected from Cl, Br, I or --OR a 4 and any remaining groups are non-displaceable groups of the formula wherein A 1 , A 2 , Q a 1 , and R a 4 are as defined above, optionally in the presence of a condensation catalyst, until formation of the desired compound is substantially complete and, if desired, reacting a product having no more than one of said displaceable groups X, Y and Z with a dialkylamine to form a dimer, self-condensing the product to an oligomer, or forming a urethane or urea compound comprising a product from any such compound having at least one of said displaceable groups by reaction with a mono- or polyol or a mono- or polyamine, and recovering said products.
DETAILED DESCRIPTION OF THE INVENTION
As starting materials to produce the urethane-functional s-triazine crosslinking agents of this invention, there can be used the triazine, such as cyanuric chloride, and/or obvious chemical equivalents thereof known in the art. Many of the starting materials are commercially available, and they can be made by well known procedures. In accordance with the present invention, the starting materials are reacted with a bis-hydroxyalkyl iminodiethylene dicarbamate made, for example, by reacting a cyclic alkylene carbonate with a polyalkylenepolyamine, such as diethylenetriamine. The preparation of the bis-hydroxyalkyl iminodiethylene biscarbamates is described in U.S. patent application Ser. No. 581,006, filed Feb. 17, 1984.
The above-cited Valko patent describes making 2-hydroxyalkyl carbamates by reacting 1,2-diols with isocyanates.
The mole ratio of beta-hydroxyalkyl carbamate to triazine compound is selected to provide the desired degree of substitution.
As will be seen by the examples herein, the reactants are mixed in suitable media, such as water-acetone-alkanol mixtures, preferably in the presence of an acid acceptor, such as sodium hydroxide, if, for example, cyanuric chloride is used as the source of the triazine ring. Low temperatures, e.g., below about 20° C. promote the formation of mono-substituted products, higher temperatures, e.g., between about 25° and 70° C. favor the formation of di-substituted products; and still higher temperatures, e.g., above about 100° C. favor tri-substitution. Recovery of the product is conventional, e.g., by precipitation and washing free of any acidic byproduct or basic acid acceptor.
The monomeric products of the process can be self-condensed to produce oligomeric compounds, suitable such compounds, e.g., monochlorotriazines can also be dimerized, e.g., by reacting with diamines, such as piperazine, and they can also be functionalized with amines, such as piperidine, as will be exemplified. Transesterification with alcohols, polyols, monoamines and polyamines also produce useful derivatives, as will be shown.
The substituents defined by A 1 , A 2 , Q 1 and Q 2 , as well as R-R 7 in the Formulae above can vary widely in carbon content, and the groups can be straight chain, branched chain and alicyclic. Representative compounds will be exemplified hereinafter. ##STR13##
The composition containing the crosslinking agents, polymers, and, optionally, catalyst, is heated to an elevated temperature at which the hydroxyalkyl carbamate groups of the cross-linker react with active functional groups of the polymer to cross-link the polymer and produce diol leaving groups of low toxicity, such as propylene glycol or ethylene glycol. A typical reaction sequence of, for example, a hydroxy functional group containing polymer of shown in equation (1) and that for an amine functional group containing polymer is shown in equation (2). ##STR14##
With carboxyl functional group polymers, amide groups are formed in the reaction and the reaction products of the cross-linking reaction are CO 2 and the corresponding 1,2-diol. Generally, the leaving groups in the cross-linking reaction are, as illustrated above, diols of low toxicity, such as propylene glycol or ethylene glycol. Any attempt to prepare the above described hydroxyalkyl carbamate compounds by reaction of a diisocyanate with a di- or polyol would be difficult or impossible inasmuch as the formation of polyurethane polymers or gelation would occur.
The amount of hydroxyalkyl carbamate selected in a typical formulation will of course depend on the cross-linking density desired. Typically, the proportion and compositions of resin and cross-linker are selected to provide from about 0.2 to about 5 moles of hydroxyalkyl carbamate groups per mole of active functional group on the polymer. If larger proportions of cross-linker carbamate groups to functional sites on the polymer are used, the cross-linker will also undergo some self-condensation, as shown in equation (3). ##STR15##
The cross-linkable resins utilizable in the present invention may comprise any suitable polymer containing active hydrogen functional groups, i.e., suitable functional groups which will react, upon heating, preferably upon heating in the presence of a catalyst, with the urethane functional groups on the cross-linker of the invention. Such active groups comprise hydroxyl, amine, amide, thiol and carboxyl groups and, accordingly, resins containing such groups are utilizable in the practice of the invention. The functionality of the polymers employed can be as low as 2 but is preferably 3 or higher, and the molecular weight may range, for example, from about 300 to about 100,000. For example, acrylic polymers useful in the invention usually have a molecular weight range of from about 1,000 to about 50,000.
A typical functional group content of, for example, hydroxyl resins utilizable in the invention is from about 0.5 to about 4 milliequivalents ("meq") hydroxyl per gram of resin solids.
An illustrative, but by no means exhaustive, list of polymers which may be usefully employed in the invention includes acrylic, polyester, vinyl, epoxy, polyurethane, polyamide, cellulosic, alkyd and silicone resins. Acrylic resins useful in the invention can be derived from the acrylic acid or methacrylic acid esters of C 1 to C 18 aliphatic alcohols. Optionally, acrylonitrile, styrene or substituted styrene can be incorporated into the polymer. Additional comonomers suitable for such use are maleic or fumaric acid esters or half esters. Functional groups can be derived from the hydroxyalkyl esters of acrylic, methacrylic, maleic or fumaric acid. Carboxyl functionality can be derived from alpha and beta unsaturated carboxylic acids such as those mentioned below.
Polyester and alkyd resins suitable for use with the urethane-functional triazine cross-linker can be derived from diols, polyols, mono-, di-, and polybasic acids. Examples of such suitable diols or polyols are ethylene glycol, propylene glycol, 1,3-butylene glycol, diethylene glycol, dipropylene glycol, neopentyl glycol, trimethylpentane diol, cyclohexanedimethanol, trimethylolpropane, trimethylolethane and glycerine pentaerythritol. Typical carboxylic acids useful in preparing hydroxy and carboxyl functional polyester and alkyds are C 8 to C 18 aliphatic monocarboxylic acids, C 4 to C 10 aliphatic dicarboxylic acids, aromatic mono-, di, and tricarboxylic acids such as benzoic acid, o-, m-, p-phthalic acids, or tri-mellitic acid, dimeric fatty acids, and hydroxy carboxylic acids such as dimethylol propionic acid or caprolactone.
Vinyl polymers particularly suitable for use in the invention are hydroxy and carboxyl functional group-containing polymers containing either vinyl chloride or vinyl acetate as one of the comonomers.
Epoxy resins particularly suitable for use in the invention are hydroxy or amine functional resins. These are normally derived from bisphenol-A, bisphenol-F, or phenol formaldehyde resins and epichlorohydrin. The epoxy resins may also be formed from cycloaliphatic epoxies.
Polyurethanes particularly suitable for use in the invention may be hydroxyl, carboxyl, or amine functional and may be derived either from polyester or polyether polyols and a polyisocyanate.
Polyamides particularly suitable for use in the invention may be either amine or carboxyl functional and can be obtained by the conventional techniques of condensing polybasic acids with polyamines or by reacting polyamines with caprolactam.
Cellulose based hydroxyl functional resins such as cellulose acetobutyrate, and hydroxyethyl cellulose can also be reacted with the hydroxyalkyl carbamate-containing amines of the invention. Hydroxy functional silicones can also be cross-linked with the hydroxyalkyl carbamate cross-linker and are therefore well-suited for use in the invention.
All of the above mentioned active functional group-containing resins can be used in either organic solvent solution, as a powdered solid, or as dispersions in water or organic co-solvent aqueous solutions. Depending on resin structure, these uncross-linked polymers will be preferably used in one of the above mentioned forms. Blends of two or more of the above polymers can also be used. Further, the polymer and carbamate cross-linking agent blend may be pigmented, as is known in the art, to achieve a desired appearance of the coating.
Depending on the application process, either a solid powder or a liquid is applied onto the substrate to be coated and after evaporation of any solvent present, the system is cured for a sufficient period of time, e.g., from several minutes to several hours, at temperatures sufficient to effect cure, e.g., from about 200 to about 400° F. (about 93 to 204° C.).
A cross-linking catalyst may be used to promote cross-linking of the thermosetting composition of the invention. The catalyst may be an external catalyst or it may be incorporated as an internal catalyst during preparation of the functional group-containing resin, as is known in the art. For example, quaternary ammonium hydroxide groups may be incorporated into the resin. Any suitable crosslinking catalyst may be utilized (such as known metal-containing catalysts, e.g., lead, tin, zinc, and titanium compounds) as well as ternary or quaternary compounds as described below. Benzyltrimethyl ammonium hydroxide, dibutyltindilaurate, tetrabutyl diacetoxy stannoxane and similar compounds are good catalysts for achieving cross-linking at elevated temperatures in the range of from about 100 to about 175° C. (about 212 to about 347° F.) for a period of a few seconds to about 30 minutes. A catalyst may be present in a formulation in the amount of from about 0.1 to about 10% by weight of the polymer, preferably from about 1 to about 5% by weight of the polymer.
The catalyst may comprise ternary or quaternary catalysts such as known compounds of the formula: ##STR16## where R p , R q , R r and R s may be equivalent or different and may be a C 1 to C 20 aliphatic, aromatic, benzylic, cyclic aliphatic and the like, where M may be nitrogen, phosphorus, or arsenic (to provide, respectively, quaternary ammonium, phosphonium or arsonium compounds), where S is sulfur (to provide a ternary sulfonium compound) and where X - may be hydroxide, alkoxide, bicarbonate, carbonate, formate, acetate, lactate, and other carboxylates derived from volatile organic carboxylic acids or the like. Such salts of carboxylic acids are effective to promote the low temperature cure provided that the carboxylic acid portions of the salt are volatile.
The compositions of the present invention are stable at ambient temperature and must be heated to an elevated temperature in order to cause the cross-linking reaction to occur at an appreciable rate. Generally, an elevated temperature of about 200° F. (about 93° C.) or more is required to effectuate the cross-linking reaction at an appreciable rate. As used herein and in the claims, an "elevated" temperature is one which is sufficient to cure the deposited composition by causing the cross-linking reaction to occur at a desired rate, usually a rate sufficient to effectuate cure within a period of 1 hour or less.
In many instances a pigment composition and various conventional additives such as antioxidants, surface active agents, coupling agents, flow control additives, and the like, can be included. The pigment composition may be of any conventional type, such as, one or more pigments such as iron oxides, lead oxides, strontium chromate, carbon black, titanium dioxide, talc, barium sulfate, cadmium yellow, cadmium red, chromic yellow, or the like.
After deposition on a substrate, such as a steel panel, the coating composition is devolatilized and cured at elevated temperatures by any convenient method such as in baking ovens or with banks of infrared heat lamps or in microwave ovens. Curing can be obtained at temperatures in the range of from 120° C. to about 300° C., preferably from 150° C. to about 200° C. for from about 30 minutes at the lower temperatures to about 1 minute at the higher temperatures.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following examples illustrate the compounds and compositions of the present invention. They are not to be construed as limiting the claims in any manner. All parts are by weight.
EXAMPLE 1
2,4-Bis[N,N-bis[(2-hydroxyethoxycarbonylamino)-ethyl]amino]-6-chloro-s-triazine (TECT) (I)
To 50 g water in a 3-neck flask equipped with stirrer and a thermometer, were added 9.2 g (0.05 m) of cyanuric chloride, dissolved in 50 g acetone below 10° C. To the white slurry of cyanuric chloride, 27.9 g of bis(2-hydroxyethyl) (iminodiethylene)biscarbamate (HEC), NH(CH 2 CH 2 NHCO 2 CH 2 CH 2 H) 2 dissolved in 50 g of water was added over a period of 15 minutes. During the addition, the reaction temperature was maintained below 12° C. After complete addition of HEC, the slurry turned into a clear solution. To this was added 10% caustic to maintain the reaction pH at about 7 and the reaction mixture was allowed to warm up to 25° C. At 25° C., as the reaction progressed, a white crystalline solid slowly separated out. After 4 hrs. at 25-35° C., the solids were separated by filtration, washed with water and recrystallized from ethanol. The product yield was 24 g and m.p. 174° C. The structure of the product was confirmed by nuclear magnetic resonance (nmr) and fast atomic bombardment (fab), mass spectrometry to be that of FORMULA I: ##STR17##
EXAMPLE 2
Hexakis[2-(2-hydroxyethoxycarbonylamino)ethyl]melamine (HECM)(II)
To 6.7 g of (I) (Example 1, TECT) were added 2.8 g HEC, 0.84 g sodium bicarbonate and 25 g ethylene glycol. The reaction mixture was then heated to 115° C. in an oil bath for 4 hours, after which most of the HEC had reacted with TECT as indicated by amine titration of the reaction mixture. Ethyelene glycol was distilled off under reduced pressure. The residue was poured into methanol. Separated solids were filtered and recrystallized from methanol. Yield 5.6 g (60% of theoretical), m.p. 192° C. The nmr and fab mass spectra confirmed the product to be of FORMULA II: ##STR18##
EXAMPLE 3
Hexakis[2-(2-hydroxypropoxycarbonylamino)ethyl]melamine (HPCM) (III)
As in Example 1, 9.2 g (0.05 m) of cyanuric chloride was slurried into water in a suitably equipped 3 neck flask. To the slurry was added 78 g (0.02 m) of bis(2-hydroxypropyl) (iminodiethylene)bis carbamate (HPC), an isomeric mixture of NH(CH 2 CH 2 NHCO 2 CH(CH 3 )CH 2 OH) 2 and NH(CH 2 CH 2 NHCO 2 CH 2 CH(CH 3 )OH) 2 , (80% by weight in isobutanol) below 10° C. After complete addition of HPC to the reaction mixture, the temperature of the mixture was allowed to rise to 25° C. A clear, pale yellow solution was obtained. The clear solution after several hours at 25° C. was treated with Dowex® 1×8 (OH - ) anion exchange resin to remove HCl. The HCl free solution was then stripped under reduced pressure to remove acetone and water. The water-free syrupy residue, 90 g, and 100 g of propylene glycol were heated on an oil bath to 115° C. for 4 hours. The total free amine in the mixture was 36 meq. The reaction mixture in methanol was treated first with Dowex® 1×8(OH - ) and subsequently with Dowex® 50W×8(H + ) ion exchange resins to remove Cl - and free HPC. After removal of methanol and ethylene glycol under reduced pressure a white solid product was obtained. Its structure was confirmed by spectroscopy to be of FORMULA III: ##STR19## wherein R 1 , R 2 and R 3 are --N(CH 2 CH 2 NHCO 2 CH(CH 3 )CH 2 OH) 2 or --N(CH 2 CH 2 NHCO 2 CH 2 CH(CH 3 )OH) 2
The product (III) as shown by the above formula was an isomeric mixture of compounds containing primary and secondary hydroxy groups. The yield was 32 g (64% of theory), and the melting point was 110-120° C.
EXAMPLE 4
2,4-Bis[N,N-bis[(2-hydroxypropoxy carbonylaminoethyl)amino]-6-chloro-s-triazine (TPCT) (IV)
In a suitably equipped 3-neck flask, 9.2 g (0.05 m) of cyanuric chloride solution in 50 g of acetone was slurried in 50 g of water below 10° C. To this was added slowly 38.8 g of HPC (80% in isobutanol) dissolved in 50 g of water below 10° C., maintaining temperature of the reaction mixture. At the complete addition of HPC, the reaction mixture turned into a clear, pale yellow solution. The batch temperature was allowed to rise while maintaining the pH of 6-7 by slow addition of 10% caustic solution to the batch. After completion of the reaction (after 3-4 hours at 25-30° C.) water was removed from the reaction mixture by azeotroping with n-butanol under reduced pressure. The separated sodium chloride was filtered off. The clear filtrate was vacuum stripped to remove butanol. After the removal of butanol, a syrupy product was obtained, which on long standing, solidified. The mass spectrum of the syrup product indicated it to be of FORMULA IV: ##STR20## wherein R 2 and R 3 are --N(CH 2 CH 2 NHCO 2 CH(CH 3 )CH 2 OH) 2 or --N(CH 2 CH 2 NHCO 2 CH 2 CH(CH 3 )OH) 2 (IV)
The solidified product (TPCT), which is an isomeric mixture as shown by the above formula, was crystallized from acetone. The yield was 6 g and the melting point was 135-140° C.
EXAMPLE 5
Reaction of FORMULA I (TECT) with Piperidine
In a suitable equipped round bottom flask were charged 6.7 g of the product of Example 1 (TECT)(0.01 m), 0.85 g (0.01 m) of piperidine and 0.85 g of sodium bicarbonate and 25 g of ethylene glycol. The mixture was heated on an oil bath to 115° C. for 4 hours. The total free base after this reaction period was 1.4 meq. Ethylene glycol was removed by distillation under reduced pressure below 150° C. The resinous product was dissolved in methanol. The separated sodium chloride was filtered off and washed with small amounts of methanol. After removal of methanol from the reaction product, a glassy solid was obtained. Mass spectra of the product indicated it to be of FORMULA V: ##STR21##
EXAMPLE 6
Reaction of FORMULA IV (TPCT) with Piperidine
In a suitable equipped round bottom flask were charged 43.5 g (0.06 m) of the product of Example 4 (TPCT), 11.5 g (0.13 m) of piperidine, 5.43 g (0.06 m) of sodium bicarbonate, and 96 g of propylene glycol mono-methyl ether. The mixture was heated at 120° C. for 5 hours. Sodium chloride was separated from the product by filtration. Dowex® 50W×8(H+) ion exchange resin was added to the solution and stirred 30 minutes to remove excess amine. The resin beads were separated from the product by filtration. The propylene glycol mono-methyl ether was stripped from the product under vacuum at 110° C. The product was a resinous material. Mass spectra indicated the compound to be of Formula VI: ##STR22## wherein R 2 and R 3 are --N(CH 2 CH 2 NHCO 2 CH(CH 3 )CH 2 OH) 2 or --N(CH 2 CH 2 NHCO 2 CH 2 CH(CH 3 )OH) 2 (VI)
EXAMPLE 7
Reaction of FORMULA IV (TPCT) with Dodecylamine
In a reaction vessel were charged 16.6 g (0.02 m) of the product of Example 4 (TPCT), 8.5 g (0.04 m) of dodecylamine, 1.9 g (0.02 m) of sodium bicarbonate, and 50 g of propylene glycol monomethyl ether. The mixture was heated at 115° C. for 2.5 hours. Sodium chloride was separated from the product by filtration. Dowex® 1×8(OH-) ion exchange resin was added and the mixture was stirred 30 minutes to remove free chloride ions. The resin beads were filtered out and Dowex® 50W×8(H+) ion exchange resin was added. The mixture was stirred 30 minutes to remove excess amine and then the resin beads were removed by filtration. The propylene glycol monomethyl ether was stripped from the product under vacuum at 110° C. The product was resinous material. Mass spectra indicated the compound to be of FORMULA (VII): ##STR23## wherein R 1 and R 2 are --N(CH 2 CH 2 NHCO 2 CH(CH 3 )CH 2 OH) 2 or --N(CH 2 CH 2 NHCO 2 CH 2 CH(CH 3 )OH) 2 (VII)
EXAMPLE 8
REACTION OF FORMULA I (TECT) WITH PIPERAZINE
In a suitable equipped round bottom flask were charged 14.85 g (0.02 m) of the product of Example 1 (TECT), 0.987 g (0.01 m) of piperazine, 1.89 g (0.02 m) of sodium bicarbonate, and 53 g of propylene glycol mono-methyl ether. The mixture was heated at 115° C. for 5 hours. The propylene glycol monomethyl ether was stripped from the product under vacuum at 110° C. The solid product was washed with water to remove sodium chloride. The product was finally dried to remove water. Mass spectra indicated the product to be of FORMULA VIII: ##STR24## R 1 and R 2 are --N(CH 2 CH 2 NHCO 2 CH 2 CH 2 OH) 2 (VIII)
EXAMPLE 9
REACTION OF FORMULA IV (TPCT) WITH PIPERAZINE
In a suitably equipped round bottom flask were, charged 32.6 g (0.045 m) of the product of Example 4 (TPCT), 1.3 g (0.015 m) of piperazine, 3.8 g (0.045 m) of sodium bicarbonate, and 61 g of propylene glycol monomethyl ether. The mixture was heated at 115° C. for 4 hours. Sodium chloride and sodium bicarbonate were separated from the product by filtration. The propylene glycol monomethyl ether was stripped from the product under vacuum at 110° C. The product was a resinous material. Mass spectra confirmed the structure to be of FORMULA IX: ##STR25## wherein R 1 and R 2 are --N(CH 2 CH 2 NHCO 2 CH(CH 3 )CH 2 OH) 2 or --N(CH 2 CH 2 NHCO 2 CH 2 CH(CH 3 )OH) 2 (IX)
EXAMPLE 10
Preparation of 2-Bis[N,N-bis[(2-hydroxypropoxy carbonylaminoethyl]-amino-4,6-dichloro-s-triazine (X)
To a reaction vessel is added 15.6 g (0.05 m) of bis(2-hydroxypropyl)(iminodiethylene)bis carbamate dissolved in 50 g of N-butanol. To this solution is added 4.2 g of sodium bicarbonate. Then, at 0-5° C., is added slowly 9.2 g (0.05 m) of cyanuric chloride dissolved in 75 g of ethyl acetate. The reaction mixture is allowed to stir at 0-5° C. and progress of the reaction was monitored by thin layer chromatography (tlc). As soon as all the cyanuric chloride is converted to monosubstituted product, the reaction mixture is filtered and washed with ethyl acetate to separate sodium chloride from the filtrate. The product is isolated by removing ethyl acetate and n-butanol under reduced pressure.
EXAMPLE 11
Preparation of 2-Bis[N,N-bis[(2-hydroxyethoxy carbonyl aminoethyl]amino]4,6-dichloro-s-triazine (XI)
This compound is prepared by the same procedure as in Example 10 except that cyanuric chloride (0.05 m) is reacted with bis(2-hydroxyethyl)(iminodiethylene)biscarbamate (0.05 m).
EXAMPLE 12
Preparation of 2,4-bis[N,N-bis[(2-hydroxypropoxy carbonyl aminoethyl]-amino]-6-di-n-butylamino-s-triazine (XII)
In a suitably equipped round bottom flask were charged 21.75 g (0.03 m) of the product of Example 4 (TPCT), 4.65 g (0.036 m) of di-n-butylamine, 2.52 g (0.03 m) of sodium bicarbonate, and 200 g n-butanol. The mixture was heated to reflux (118-120° C.) for 4.5 hours. The reaction was followed by thin layer chromatography (tlc). The reaction was stopped when practically all of IV was converted to the product. The reaction mixture was filtered to remove sodium chloride. The trace amount of di-n-butyl amine was removed by Dowex® 50W×8(H+) ion exchange resin. After removal of n-butanol the product was recrystallized from ethyl acetate. Yield: 17 g (69% of theory) mp 125-130° C. N.m.r. of the product confirmed the structure as shown below. The product is soluble in common organic solvents used in coatings. ##STR26## wherein R 1 and R 2 are --N(CH 2 CH 2 NHCO 2 CH 2 (CH 3 )CH 2 OH 2 ) 2 or --N(CH 2 CH 2 NHCO 2 CH(CH 3 )OH) 2 (XII)
EXAMPLE 13
Preparation of 2,4-bis[N,N-bis[(2-hydroxypropoxy carbonyl amino ethyl]-amino]-6-di-iso-butylamino-s-triazine (XIII)
In a suitably equipped round bottom flask were charged 21.5 g (0.03 m) of the product of Example 4 (TPCT), 4.65 g (0.036 m) of diisobutylamine, 2.52 g (0.03 m) of sodium bicarbonate, and 60 g 2-propoxypropanol. The mixture was heated to reflux for 7 hours. tlc shows practically all product and only a trace amount of IV. The reaction mixture was worked up as in Example 12. After removal of solvent a sirupy product was obtained. On complete drying a glassy solid was obtained m.p., ˜55° C. The yield was quantitative. The n.m.r. confirmed the structure as shown below. The product is soluble in common organic solvents such as methyl ethyl ketone, toluene, ethyl acetate, n-butanol, etc. It is insoluble in water. ##STR27## wherein R 1 and R 2 are --N(CH 2 CH 2 NHCO 2 CH(CH 3 )CH 2 OH 2 ) 2 or --N(CH 2 CH 2 NHCO 2 CH 2 CH(CH 3 )OH) 2 (XIII)
EXAMPLE 14
Preparation of 2-bis[N,N-bis[(2-hydroxy propoxy carbonyl aminoethyl]-amino]-4,6-dibutylamino-s-triazine (XIV)
This compound is prepared in two steps. First the compound described in Example 10 is prepared without isolating it. Then, to this product 8.4 g NaHCO 3 , and 12.9 g (0.lm) of di-n-butylamine are added and the reaction temperature is raised slowly to 115° C., after distilling off ethyl acetate. The reaction temperature is maintained at 115° C. for several hours to complete the substitution of chlorine atoms by dibutylamine. After the reaction is complete, sodium chloride formed during the reaction is filtered off. After removal of n-butanol the desired product is obtained.
EXAMPLE 15
Preparation of 2-bis[N,N-bis[(2-hydroxypropoxy carbonyl aminoethyl]-amino]-4,6-dianilino-s-triazine (XV)
This compound is prepared by following the procedure of Example 14, but instead of di-n-butylamine, aniline (9.2 g, 0.lm) is used.
EXAMPLE 16
Preparation of 2-bis[N,N-bis[(2-hydroxypropoxy carbonylaminoethyl]-amino-4-butylamino-6-anilino-s-triazine (XVI)
To a suitably equipped 3-necked flask, are added 15.6 g (0.05 m) of bis(2-hydroxypropyl)(imino diethylene)bis carbamate dissolved in 50 g of n-butanol. To this solution are added slowly 9.2 g (0.05 m) of cyanuric chloride dissolved in 75 g of ethylacetate. The reaction mixture is allowed to stir at 0-5° C. and progress of the reaction is monitored by tlc. After all the cyanuric chloride is reacted to the mono substituted product, 8.4 g of sodium bicarbonate and 3.65 g (0.05 m) of n-butylamine are added. The reaction temperature is raised to 35-45° C. and maintained there until most of the n-butylamine has reacted. At this point 4.7 g (0.05 m) aniline are added and the reaction temperature raised to 115° C. after distilling out ethyl acetate. After about 5-6 hours, sodium chloride is filtered off. After removal of n-butanol and reaction work up and above-described product is obtained in high yields. ##STR28## wherein R 1 is --N(CH 2 CH 2 NHCO 2 CH(CH 3 )CH 2 OH) 2 or --N(CH 2 CH 2 NHCO 2 CH 2 CH(CH 3 )OH) 2 (XV)
EXAMPLE 17
Transesterification of FORMULA III to Produce Crosslinker XVII
In an autoclave were charged 100 g (0.1 m) of the compound of Example 3 (HPCM)(III), 225 g (3.0 m) of n-butanol, and 1.2 g of dibutyltindilaurate catalyst. The autoclave was heated in an oil bath on a magnetic stirrer hot plate to 155° C. The reaction mixture was kept in the oil bath at 155° C. for 5 hours. The pressure in the autoclave was about 40 psi. The resulting product mixture was a clear yellow solution. It was soluble in common organic solvents at room temperature. It was also miscible with commercially available acrylic resins and polyesters. The clear solution was concentrated to 45% solids. The proton n.m.r. of the product showed that about 40% of hydroxypropylcarbamate groups were transesterified with n-butanol. The average distribution of the hydroxypropylcarbamate to butylcarbamate was 2:3. The transesterification reaction is shown below: ##STR29##
EXAMPLE 18
Preparation of Crosslinker XVIII
In an autoclave were charged 100 g (0.lm) of the compound of Example 3 (HPCM)(III), 320 g (2.7 m) of 2-propoxy-propanol, and 1.2 g of dibutyltindilaurate catalyst. The autoclave was heated in an oil bath on a magnetic stirred hot plate to 155° C. The reaction mixture in the autoclave was stirrer with a magnetic stirrer. The reaction mixture was kept in the oil bath at 155° C. for 6 hours. After this period the resulting product mixture was a pale amber solution It was soluble in common organic solvents it was also misible with commercially available polyesters and acrylic resins such as Joncryl® 500 (S.C. Johnson and Son, Inc.). The proton n.m.r. of the product showed that about 50% of hydroxypropylcarbamate groups were transesterified with 2-propoxypropanol. The average distribution of the hydroxypropyl carbamate to 2-propoxypropyl carbamate was 1:1. The product solution was concentrated to 45.3% by partial removal of 2-propoxypropanol.
EXAMPLE 19
Self-Crosslinked Melamine-Urethane Polymer Film
2.2 g of the reaction product of piperidine and TECT (Compound V from Example 5) was dissolved in n-butanol. To this butanol solution were added 2 drops of benzyltrimethylammonium hydroxide (40%) and a drop of 1% solution of fluorocarbon surfactant FC 431 in n-butanol. The clear, pale yellow blend was cast as a film on a zinc phosphate treated cold rolled steel panel and baked at 150° C. for 20 minutes. The resulting film was very hard and glass-like, and had excellent resistance to acetone. The film thickness was 0.6 mil, Knoop hardness was 37, pencil hardness was greater than 5H and it passed the 1/8" mandrel bend test.
EXAMPLE 20
A hydroxy-functional acrylic resin was prepared by copolymerizing a blend of n-butyl acrylate (60 wt %), styrene (20 wt %), and 2-hydroxyethyl methacrylate (20 wt %), using dicumyl peroxide initiator and n-dodecyl mercaptan chain transfer agent. The polymerization was carried out in 2-ethoxyethanol at reflux temperature (135-140° C.).
Ten grams of 75% solution of a hydroxy functional acrylic resin was blended with 2.5 g of crosslinker of FORMULA III (HPCM), 0.3 g tetrabutyl diacetoxy stannoxane catalyst and 5 g n-butanol. The blend was warmed to make it homogenous. The well-mixed homogenous blend was cast on a zinc phosphate treated cold rolled steel panel using #22 Wirecator®. The films were baked at 150° C. and 175° C. for 20 minutes respectively. The film properties are shown in Table 1.
TABLE 1______________________________________Properties of Acrylic Coatings A B______________________________________Bake schedule 20'/150° C. 20'/175° C.Film thickness 0.8 mil 0.9 milPencil hardness 2B-B HB-FImpact resistance (Reverse) 80 in.lbs. 80 in.lbs.MEK resistance (Double Rub) 100+ 100+Humidity resistance (140° F.) Passes 2 wks. Passes 3 wks.______________________________________
EXAMPLE 21
Four formulations were prepared by blending a commercially available polyester resin Multron® 221-75 (Mobay), crosslinker FORMULA III (HPCM) and a tin catalyst. Amounts of each component are shown in Table 2. The 175° C. baked films obtained from formulation E and F were essentially crosslinked as indicated by MEK rubs. Films from formulations C and D required 200° C. bake to achieve crosslinking. Films from formulations E and F had 200°+ MEK rubs. These results show that tetrabutyl diacetoxy stanoxane (TBDAS) is a more effective catalyst than dibutyltin dilaurate (DBTL) in these formulations.
TABLE 2______________________________________Properties of Polyester - HPCM Coatings C D E F______________________________________Multron ® 221-75 16 g 15 g 15 g 16 gCrosslinker III 4 5 5 4DTL 0.2 0.2 -- --TBDAS -- -- 0.2 0.2n-BuOH 8 8 8 8Bake Schedule175° C./20' No cure 35 175 100(MEK rubs)200°/20' 70 85 200+ 200+(MEK rubs)______________________________________
The results reported in Tables 1 and 2 demonstrate that the compound of FORMULA III (HPCM) functions as a cross-linker to cross-link acrylic and polyester thermoset resins with pendant hydroxy groups. The reduced cure response of the polyester resin versus that of the acrylic resin is due to the fact that the polyester resin has residual acid (acid number 10) while the acrylic resin is free of any acid (acid number 2). The presence of nonvolatile acid in the film results in retardation of cure rate of transesterification reaction required for cross-linking.
EXAMPLE 22
Modification of FORMULA III (HCPM) for Use as Crosslinker For Cathodic Electro Coating (EC) Compositions
9.96 g (0.01 m) of HPCM (Example 3) and 65 g (0.05 m) of 2-ethylhexanol were heated together to 155-160° C. in the presence of 2 g of tetrabutyl diacetoxy stannoxane for 61/2 hours. After this period, 2-ethylhexanol was distilled off under reduced pressure at 150-160° C. A white creamy solid residue was obtained (17 g) which dissolved in n-butanol (4.7 g) to a clear amber colored solution. Mass Spectra of the product indicated the product mainly to be a mixture of the following: ##STR30##
The product was insoluble in water and very hydrophobic. These properties make the product a suitable cross-linker for cathodic EC compositions. Similar hydrophobic cross-linkers can be prepared by oligomerization and by transesterification of FORMULA III (HPCM) with hydrophobic alcohols. Other hydrophobic s-triazine compounds with pendant hydroxyalkylcarbamate groups, carbamate groups or mixture of hydroxyalkyl carbamate groups can be used in cathodic electrocoating as crosslinking agents. The cross-linking ability of the product of this Example 22 is demonstrated in Example 23 by cross-linking a cationic resin suitable for cathodic electrocoating.
EXAMPLE 23
Nine and three-tenths grams of a cationic resin (prepared according to U.S. Pat. No. 3,984,299, adduct C) was blended with 6 g of the product of Example 22 (50% solution) along with 0.1 g of dibutyltin dilaurate catalyst. The blend was cast on a steel panel and baked at 175° C./20'. The film after the bake had a film thickness of 1 mil; a pencil hardness of 3H; and a MEK rub resistance of 75-100.
EXAMPLE 24
To show efficacy of crosslinking agents of FORMULAE XII, XIII, XVII, and XVIII, clear formulations were prepared using hydroxy functional acrylic and polyester resins as shown in Table 3. A formulation was also prepared with an acrylic resin and methylated melamine-formaldehyde resin, used widely in many industrial coatings (Control No. 7).
TABLE 3__________________________________________________________________________Coating FormulationsFORMULATION 1 2 3 4 5 6 7COMPOSITION (this invention) (control)__________________________________________________________________________Acrylic Resin.sup.1 -- -- 3.6 7.6 10 9.3 57.2Joncryl ® 500.sup.2 3.3 -- -- -- -- -- --Cargill 5776.sup.3 -- 2.9 -- -- -- -- --Crosslinker XII -- 0.9 -- -- -- -- --Crosslinker XIII.sup.4 -- -- -- -- 3.4 4 --75% solutionCrosslinker XVII.sup.5 -- -- 1.65 4.2 -- -- --Crosslinker XVIII.sup.6 1.7 -- -- -- -- -- --Cymel ® 3037 -- -- -- -- -- -- 12.5TBDAS.sup.8 0.03 0.03 0.036 0.1 0.1 0.1 --n-DDBSA.sup.9 -- -- -- -- -- -- 0.3Resin/Crosslinker 77/23 75/25 75/25 75/25 75/25 70/30 75/25Ratio__________________________________________________________________________ .sup.1 Acrylic polymer prepared by copolymerizing nbutyl acrylate (50 wt %), styrene (30 wt %), and 2hydroxy ethyl methacrylate (20%). Hydroxy No. 94, 75% solution in 2propoxypropanol. .sup.2 A commercially available resin from Johnson Wax. .sup.3 A commercially available polyester resin from Cargill. .sup.4 75% solution in 2methoxypropanol. .sup.5 45% solution in nbutanol. .sup.6 48.5% solution in 2propoxypropanol. .sup.7 methylated melamineformaldehyde resin available commercially from American Cyanamid Company (Control). .sup.8 Tetrabutyl diacetoxy stannoxane. .sup.9 ndodecylbenzenesulfonic acid, 70% solution.
The formulations were cast on zinc phosphate pretreated steel panels and the films were baked at 150° C. and 175° C. respectively. In case of formulation 2, the films were cast on aluminium panels and baked at 260° C. for 60 seconds, commonly used in coil coating. The results of testing are set forth in Table 4:
TABLE 4__________________________________________________________________________FILM PROPERTIESFORMULATION 1 2* 3 4 5 6 7__________________________________________________________________________Bake Schedule 175 260 150 175 150 175 150 175 150 175 150 175°C./min. 20 20 20 20 20 20 20 20 20 20 20 20Film Thickness 0.7 0.6 1.0 0.7 0.8 0.8 0.7 0.6 0.7 0.5 1.0 1.0(mils)Knoop Hardness 11.8 -- 11.2 11.0 4.8 11.5 8.6 11.0 8.3 13.2 10.9 12.6Pencil Hardness 2H 2H F-H H F 2H H 2H H 2H H HHumidityResistance 3 wks -- -- -- -- -- 3 wks 3 wks 3 wks 3 wks 3 wks 3 wks(140° F.) N.C.** -- -- -- -- -- N.C. N.C. N.C. N.C. 8B 7BSalt SprayResistance 10; -- -- -- -- -- 6; 9; 6; 9; 5; 5;(240 hrs) 0 mm 3 mm 0 mm 2 mm 0 mm 10 mm 10 mmMEK Double Rub 200+ 200+ 200+ 180 200+ 200+ 200+ 200+ 200+ 200+ 200+ 200+T-Bend T3 passesImpact (Rev.) 0-10 50 50 50 50 30-40 50 50 50 50 0-10 0-10in.lbs.__________________________________________________________________________ *Films were cast on aluminum panels Alodine ® 1200s **N.C. no corrosion
Film properties in Table 4 show that crosslinked films obtained by utilizing crosslinking agents of FORMULAE XII, XIII, XVII and XVIII have good solvent resistance, excellent hardness, and good flexibility. The humidity and salt spray resistance of these films is also superior to the films obtained from the acrylic-methylated melamine-formaldehyde crosslinking agent based control formulation. The other advantage is that the formulations are formaldehyde free.
Experiments have also shown that, in unpigmented coatings, crosslinked films obtained by using the novel urethane-functional s-triazine crosslinker XVII had better corrosion resistance, humidity resistance and better post-forming properties as compared with films obtained with commercially available alkylated melamine formaldehyde crosslinkers as in control formulation 7.
EXAMPLE 25
Transesterification of FORMULA III (HPCM) with 2-Butoxyethanol
50 g (0.05 m) of HPCM (III, Example 3) and 295 g of 2-butoxyethanol were heated to reflux at 160° C. in the presence of 5 g of tetrabutyl diacetoxy stannoxane for four hours. The excess 2-butoxyethanol and propylene glycol formed during the reaction were removed under reduced pressure. The viscous residue was dissolved in methanol. On standing, the tin catalyst separated from the solution. It was filtered off and an amber colored residue was dissolved in n-butanol, solids, content, 50.4%. The product was insoluble in water. The expected structure of the product having pendant 2-butoxyethylcarbamate groups is shown below. The infrared spectrum was consistent with a product of FORMULA XXV. ##STR31## R 1 and R 3 are --N(CH 2 CH 2 NHCO 2 CH 2 CH 2 OC 4 H 9 ) 2 and R 2 is --N(CH 2 CH 2 NHCO 2 CH(CH 3 )CH 2 OH) 2 (XXV)
EXAMPLE 26
Preparation of Cationic Acrylic Polymer and Cross-linking with Compound (XXV)
A cationic acrylic polymer with pendant hydroxy groups (Hydroxy number 90) was prepared according to U.S. Pat. No. 4,026,855 (1977), described as cationic polymeric material E in column 8. There were three minor changes (i) instead of 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate was utilized; (ii) the monomer-acrylic acid ester of methoxy polyethylenoxyglycol (55) was eliminated; and (iii) the final resin solids were 76%. Thirty-five grams of the cationic acrylic resin, 23 g of crosslinking agent of Example 25, 12.5 g rutile titanium dioxide OR®600, 0.5 g acetic acid, and 0.5 g of tetrabutyl diacetoxy stannoxane were blended together on high speed stirrer to obtain good dispersion and wetting of the pigment. To this was slowly added deionized water to make up the final volume of the paint dispersion to 500 ml. The final paint solids were 10%, the bath pH was 4.9 and bath conductivity was 440 Ohm -1 cm -1 . The bath was allowed to age overnight at room temperature. Next day phosphate coated steel panels (BO 100®) were electrocoated using stainless steel anode. The deposition characteristics and film properties after baking for 20 minutes are shown in Table 6.
TABLE 5__________________________________________________________________________Electrodeposited Cross-linked Acrylic CoatingsDeposition Time (Depositing) Bake Film Thickness Knoop Impact (rev.) MEK RubVoltage(v) (secs) Temp.°C. (mil) Hardness in.lb. Resistance__________________________________________________________________________100 60 150 0.62 11.2 -- 200+100 90 150 0.6 11.2 -- 200+100 90 175 0.6 12.0 -- 200+200 60 150 1.0 6.8 40+ 200+200 60 175 1.0 12.5 20-30 200+250 30 150 1.0 6.9 40+ 200+250 30 175 1.0 12.6 20-30 200+__________________________________________________________________________
The results in Table 6 show that the bath had good electrodeposition characteristics and films were completely crosslinked at 150° C. in 20 minutes. However, the electrocoating bath showed signs of instability after two weeks of aging at room temperature.
EXAMPLE 27
A coating composition is prepared comprising an acrylic resin which is a copolymer of n-butyl acrylate, styrene and 2-hydroxyethyl methacrylate in 2-ethoxyethanol (solids 75%, hydroxy number, 85), 18.7 g, Compound of FORMULA III (HPCM), (40% in cellosolve), 15 g, and 0.2 g of tetrabutyl diacetoxy stannoxane catalyst were blended together to form a clear resinous solution. Films were cast onto phosphate treated steel panels and baked at 150° C. for 20 minutes. The films were completely cured as indicated by resistance to 200+ MEK rubs.
EXAMPLE 28
A coating composition is prepared comprising the reaction product of 1 mole of bisphenol A and 6 moles of ethylene oxide (hydroxyl number 212, Dow Chemical Co. XD-8025 polyol), 10 g, compound of FORMULA III, (HPCM) Example 3, 6 g, tetrabutyl diacetoxy stannoxane catalyst, 0.2 g, butanol, 5 g, water 2 g, blended together until clear and homogeneous. The solution was cast onto phosphate treated steel panels and baked at 150° C. for 20 minutes. The film thickness was 0.7 mil; pencil hardness FH; Knoop hardness was 5, reverse impact resistance was 80 + in.lbs.; humidity resistance at 60° C. was 21+ days; and the MEK double rub test was 200+.
The above-mentioned patents and publications are incorporated herein by reference. Many variations of this invention will suggest themselves to those skilled in this art in light of the above, detailed description. For example, instead of hydroxyfunctional polyesters and polyacrylates, epoxy resins, such as the polyglycidylethers of bisphenol A and the reaction products thereof with amines and ammonia can be used. Or, for example, the s-triazine cross-linkers of this invention may be used in other types of coating compositions, such as high solids coatings, cathodic electrocoatings and powder coatings formulations. They may also be used in polyurethane RIM (reaction injection molding) and foam formulations as one of the polyol components. All such obvious modifications are within the full intended scope of the appended claims. | Novel s-triazine compounds containing at least one N,N-bis(alkoxy or hydroxyalkoxy-carbonyl-amino C 2 -C 10 alkyl) amino substituent function in self-condensation and as cross-linkers for compounds containing active hydrogen groups. The compositions cure to coatings with excellent properties, especially corrosion resistance, humidity resistance, abrasion resistance and flexibility. The coatings have excellent exterior durability. | 55,926 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation application claiming priority to Ser. No. 12/022,636 filed Jan. 30, 2008, status allowed.
TECHNICAL FIELD
Embodiments are generally related to data-processing systems and methods. Embodiments also relate in general to the field of computers and similar technologies, and in particular to software and hardware components utilized in this field. In addition, embodiments relate to user input devices, such as keyboards, keypads, and so forth.
BACKGROUND OF THE INVENTION
With the development of compacting mobile computing technology, such as PDA (Personal Digital Assistant) devices, cellular telephones, portable media players, and so forth, current mobile devices are equipped with various functions, such as internet browsing, sending emails, camera, or games. As the functions of the mobile computing devices expand, the input interface becomes a critical issue. For example, the dimensions of current mobile devices tend to be minimized, and therefore the input interface is limited to number keyboards only or even several function keys. While the user intends to enter various alphabetic and numerical functions, such as letters, numbers, symbols, emoticons, etc., the only available approach is to enter via those number keyboards. Usually, one particular number key will represent several alphabets, and the user has to select the desired alphabet, which is an inefficient and time-consuming process often involving entering data into an options screen to change back and forth among the alphabets. Moreover, current mobile computing devices are often provided, for example, with gaming options and other applications such as streaming video and interactive texting. The keyboard configuration required for game playing, for example, is usually different from that of the conventional mobile computing device. The user, however, will also be restricted to the current available number keyboards while playing the game or utilizing an application via the mobile computing device, which significantly discourages the user from continued use of the application.
Additionally, user input areas for small portable devices such as cell phones, PDAs and media devices are inefficient and prone to input error. For most mobile devices, a standard QWERTY keyboard apparatus (virtual or physical) can be used for input. Such a keyboard was designed for two handed input with spacing between keys matching that of spacing between human fingers. Various layouts with small keys or multiple displays have been implemented in small devices; however, these are usually adaptations of the QWERTY keyboard layout and as such not optimized for input with less than two hands.
The optimization of keyboard layout for mobile devices should take into account research into the functioning of the human eye and human information processing. The following except is offered as a reference:
“From physiological studies we know several basic facts about how the eye processes information and about the physical constraints that limit how this information is presented to the brain. During a fixation, the eye has access to three regions for viewing information: the foveal, parafoveal, and peripheral. The foveal region is the area that we think of as being in focus and includes 2 degrees of visual angle around the point of fixation, where 1 degree is equal to three or four letters (thus, six to eight letters are in focus). The parafoveal region extends to about 15 to 20 letters, and the peripheral region includes everything in the visual field beyond the parafoveal region. The fovea is concerned with processing detail, with anything beyond producing a marked drop in acuity; words presented to locations removed from the fovea are more difficult to identify” (Rayner & Sereno, 1994). A copy of the unabridged article is available at the following website as a reference:
http://www.readingonline.org/research/eyemove.html
Most, if not all, input apparatuses for small devices are variations of the standard keyboard or the number pad. These input apparatuses perform poorly when operated with one or two fingers as required by space constrained mobile devices. Circular and semi-circular inputs apparatuses are known in the art; however these apparatuses are designed for two finger or greater input and lack the dynamic rearrangement features required for efficient input on mobile devices.
Therefore, there is a need for an improved mobile computing input interface that a user can utilize more conveniently. There is also a need for an improved input interface that facilitates the minimization of the mobile computing device. It is believed that the embodiments described in greater detail herein offer a solution to these current drawbacks.
BRIEF SUMMARY
The following summary is provided to facilitate an understanding of some of the innovative features unique to the present invention and is not intended to be a full description. A full appreciation of the various aspects of the embodiments disclosed herein can be gained by taking the entire specification, claims, drawings, and abstract as a whole.
It is, therefore, one aspect of the present invention to provide for an improved data-processing method, system and computer-usable medium.
It is another aspect of the present invention to provide for a method, system and computer-usable medium for providing a virtual self-adapting keyboard.
It is a further aspect of the present invention to provide for a method, system and computer-usable medium for providing a circular keyboard for use with small input devices.
The aforementioned aspects and other objectives and advantages can now be achieved as described herein. A method, apparatus and computer-usable medium are described herein for implementing virtual keyboards for use with small input devices. A circular keyboard can be graphically displayed, in response to a user input by a user via a small input device. A circular and centrally located key can be graphically positioned and displayed within the center of the circular keyboard, wherein character keys radiate outward from the circular and centrally located key (i.e., the “central key”) Character keys that are most commonly utilized by the user are preferably located closer to the circular and centrally located key within the circular keyboard. Character keys least commonly utilized by the user are preferably located at the edges of the keyboard, thereby permitting the circular keyboard to function as a self-adapting virtual keyboard for use with small input devices based on the usage of the keyboard by the user.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying figures, in which like reference numerals refer to identical or functionally-similar elements throughout the separate views and which are incorporated in and form a part of the specification, further illustrate the present invention and, together with the detailed description of the invention, serve to explain the principles of the present invention.
FIG. 1 illustrates a schematic view of a computer system in which the present invention may be embodied;
FIG. 2 illustrates a schematic view of a software system including an operating system, application software, and a user interface for carrying out the present invention;
FIG. 3 depicts a graphical representation of a network of data processing systems in which aspects of the present invention may be implemented;
FIG. 4 illustrates a virtual keyboard apparatus that can be adapted for use with a small input device in order to improve the speed and accuracy of user input to such a small input device, in accordance with a preferred embodiment;
FIG. 5 illustrates a small input device adapted for use with the virtual keyboard apparatus depicted in FIG. 4 , wherein the small input device includes a display screen and a rigid shell in accordance with a preferred embodiment; and
FIGS. 6, 7, and 8 respectively illustrate flow charts depicting methods for implementing the virtual keyboard apparatus of FIG. 4 , in accordance with a preferred embodiment.
DETAILED DESCRIPTION
The particular values and configurations discussed in these non-limiting examples can be varied and are cited merely to illustrate at least one embodiment and are not intended to limit the scope of such embodiments.
FIGS. 1-3 are provided as exemplary diagrams of data processing environments in which embodiments of the present invention may be implemented. It should be appreciated that FIGS. 1-3 are only exemplary and are not intended to assert or imply any limitation with regard to the environments in which aspects or embodiments of the present invention may be implemented. Many modifications to the depicted environments may be made without departing from the spirit and scope of the present invention.
As depicted in FIG. 1 , the present invention may be embodied in the context of a data-processing apparatus 100 comprising a central processor 101 , a main memory 102 , an input/output controller 103 , a keyboard 104 , a pointing device 105 (e.g., mouse, track ball, pen device, or the like), a display device 106 , and a mass storage 107 (e.g., hard disk). Additional input/output devices, such as a printing device 108 , may be included in the data-processing apparatus 100 as desired. As illustrated, the various components of the data-processing apparatus 100 communicate through a system bus 110 or similar architecture. It can be appreciated that data-processing apparatus 100 may implemented in the context, a desktop computer, computer workstation, a server, a laptop computer, and any number of small input devices, such as mobile computing devices, including cellular telephones, PDA (Personal Digital Assistant), portable medial players, and so forth.
Illustrated in FIG. 2 , a computer software system 150 is provided for directing the operation of the data-processing apparatus 100 . Software system 150 , which is stored in main memory 102 and on mass storage 107 , generally includes a kernel or operating system 151 and a shell or interface 153 . One or more application programs, such as application software 152 , may be “loaded” (i.e., transferred from mass storage 107 into main memory 102 ) for execution by the data-processing apparatus 100 . The data-processing apparatus 100 receives user commands and data through user interface 153 ; these inputs may then be acted upon by the data-processing apparatus 100 in accordance with instructions from operating module 151 and/or application module 152 .
The interface 153 , which is preferably a graphical user interface (GUI), also serves to display results, whereupon the user may supply additional inputs or terminate the session. In an embodiment, operating system 151 and interface 153 can be implemented in the context of a “Windows” system or another type of operation system such as, for example, Linux, etc. Application module 152 , on the other hand, can include instructions, such as the various operations described herein with respect to the various components and modules described herein, such as, for example, the method 600 depicted in FIG. 6 .
FIG. 3 depicts a graphical representation of a network of data processing systems in which aspects of the present invention may be implemented. Network data processing system 300 is a network of computers in which embodiments of the present invention may be implemented. Network data processing system 300 contains network 302 , which is the medium used to provide communications links between various devices and computers connected together within network data processing apparatus 100 . Network 302 may include connections, such as wire, wireless communication links, or fiber optic cables.
In the depicted example, server 304 and server 306 connect to network 302 along with storage unit 308 . In addition, clients 310 , 312 , and 314 connect to network 302 . These clients 310 , 312 , and 314 may be, for example, personal computers or network computers. Data-processing apparatus 100 depicted in FIG. 1 can be, for example, a client such as client 310 , 312 , and/or 314 . Thus, clients 310 , 312 , 314 , can be implemented as devices such as personal computers, computer workstations, PDA's, cell phones, portable media players, and so forth. Alternatively, data-processing apparatus 100 can be implemented as a server, such as servers 304 and/or 306 , depending upon design considerations.
In the depicted example, server 304 provides data, such as boot files, operating system images, and applications to clients 310 , 312 , and 314 . Clients 310 , 312 , and 314 are clients to server 304 in this example. Network data processing system 300 may include additional servers, clients, and other devices not shown. Specifically, clients may connect to any member of a network of servers which provide equivalent content.
In the depicted example, network data processing system 300 can constitute the Internet with network 302 representing a worldwide collection of networks and gateways that use the Transmission Control Protocol/Internet Protocol (TCP/IP) suite of protocols to communicate with one another. At the heart of the Internet is a backbone of high-speed data communication lines between major nodes or host computers, consisting of thousands of commercial, government, educational and other computer systems that route data and messages. Of course, network data processing system 300 also may be implemented as a number of different types of networks, such as for example, an intranet, a local area network (LAN), or a wide area network (WAN). Network 300 can also be implemented in the context of a wireless network, such as a cellular telephone network, Wi-Fi network, and so forth. The configurations depicted in FIGS. 1-3 are intended to serve as an example, and not as an architectural limitation for different embodiments of the present invention.
The following description is presented with respect to embodiments of the present invention, which can be embodied in the context of a data-processing system such as data-processing apparatus 100 , computer software system 150 and data processing system 300 and network 302 depicted respectively FIGS. 1-3 . The present invention, however, is not limited to any particular application or any particular environment. Instead, those skilled in the art will find that the system and methods of the present invention may be advantageously applied to a variety of system and application software, including database management systems, word processors, and the like. Moreover, the present invention may be embodied on a variety of different platforms, including Macintosh, UNIX, LINUX, and the like. Therefore, the description of the exemplary embodiments which follows is for purposes of illustration and not considered a limitation.
FIG. 4 illustrates a virtual keyboard apparatus 400 that can be adapted for use with a small input device (e.g., input device 500 depicted in FIG. 5 ) in order to improve the speed and accuracy of user input to such a small input device, in accordance with a preferred embodiment. FIG. 5 illustrates a small input device 500 adapted for use with the virtual keyboard apparatus 400 , and including a display screen 504 and a rigid shell 502 in accordance with a preferred embodiment. Note that in FIGS. 4-5 , identical or similar parts or elements are generally indicated by identical reference numerals. Note that display screen 504 is analogous to the display device 106 depicted in FIG. 1 , and the small input device 500 is analogous to the data-processing apparatus 100 depicted in FIG. 1 , albeit on a smaller scale. It can be appreciated that the display screen 504 (and analogous display device 106 ) can be implemented as a touch screen display.
The virtual keyboard apparatus 400 can be implemented as a keyboard displayed on a small touch screen, a thumbstick operated keyboard with an associated visual display. The virtual keyboard apparatus 400 can be alternatively implemented in the context of keys with the ability to display characters (e.g., using known OLE technology or another method). Virtual keyboard apparatus 400 can be implemented with a substantially circular keypad 401 , having keys such as number keys 1, 2, 3, etc. and letter keys A, B, C, D, etc., along with keys providing other characters such as colon, semi-colon, period, plus and minus signs, and so on. A centrally located circular central key 410 can be implemented at the center of the circular keypad 401 with character keys radiating from the central key 410 . The central key 410 may be, for example, a key such as a space key, an enter key, or another type of preferred key. In the embodiment disclosed herein, a space key is shown as the central key 410 . In other embodiments, however, the central key 410 may be another type of key, such as, for example, an enter key. The most commonly utilized characters can be placed closest to the central key 410 and the least commonly used characters positioned on the edge of the circular keypad 401 forming a part of the overall virtual keyboard apparatus 400 . Examples of such least commonly utilized keys, include, for example, shift key 402 , delete key 404 , enter key 406 , and caps lock key 408 . For devices that utilize a display and thumbstick (or button) for input, a cursor can be programmed to return to the central key 410 after each user input.
The virtual keyboard apparatus 400 is therefore optimized for single finger input by placing the keys most commonly used around a central point (e.g., central key 410 ) and placing the keys used less often further out from the center. In addition, this virtual keyboard apparatus 400 may modify the layout by relocating keys based on usage patterns to optimize key placement for frequently used keys. Such adaptive measures enable the user to input text on small devices faster than current known input apparatus.
A circular presentation for smaller key layouts is advantageous due to the way the human eye sees information. It is known that the human eye focuses on a singular point and darts around that point filling in background information. Standard keyboard layouts such as QWERTY and Dvorak require memorization for maximum efficiency. Once a keyboard becomes smaller than the hand, however, this system is inefficient and even with memorization most users must look at the keys to use them. By organizing the keyboard such that the most common keys are arranged circularly around a point, memorization becomes unnecessary since the eye can find the keys quickly, and the distance traveled to any key is less than in known layouts.
Since most users must look at smaller device keyboards to quickly input text the benefits of memorization are lessened. Additional advantages of this approach include the adaptability for both different languages and optimization for users that operate keyboards or communicate differently from the majority of known users. Further advantages of the virtual keyboard apparatus 400 exist for task oriented input tasks, such as interacting with HTML by leveraging current and future display technology to dynamically modify the keyboard layout and optimally placing keys based on the user's current input type.
Most handheld devices do not conform to the rectangular shape of the standard keyboard, yet they implement a standard keyboard layout for input. This prevents optimization of both ergonomics, aesthetics and may reduce screen space for entered text. The virtual keyboard apparatus 400 , on the other hand, can fit to almost any proportion or device design and function. The virtual keyboard apparatus 400 is likely of most value to users who do not memorize keyboard layouts and do not input on virtual devices with regularity. Such users likely include mobile device “Luddites” with a limited typing ability and who “hunt and peck” when typing.
It is known that the human eye focuses on a singular point and fills in information around that point by rapidly scanning and processing information close to that point. Virtual keyboard apparatus 400 thus represents a significant enhancement over the standard layout of keys. Improved efficiency results from a keyboard layout that may be rapidly processed by the human eye. By placing the keys most needed around the central point on the keyboard, the eye may locate a needed key faster than traditional keyboard layouts.
FIGS. 6, 7, and 8 respectively illustrate a flow chart of operations depicting methods 600 , 601 , and 603 for implementing the virtual keyboard apparatus 400 , in accordance with a preferred embodiment. Note that methods 600 , 601 and 603 can be implemented in the context of or in association with a computer-useable data storage medium that contains a program product. The methods 600 , 601 , and 603 depicted in FIGS. 6, 7 and 8 can also be implemented in a computer-usable data storage medium containing a program product.
Programs defining functions of the present invention can be delivered to a data storage system or a computer system via a variety of data storage media, which include, without limitation, non-writable data storage media (e.g., CD-ROM), writable data storage media (e.g., hard disk drive, read/write CD-ROM, optical media), and system memory such as but not limited to Random Access Memory (RAM) It should be understood, therefore, that such data storage media when storage computer readable instructions that direct method functions in the present invention, represent alternative embodiments of the present invention. Further, it is understood that the present invention may be implemented by a system having means in the form of hardware, software, or a combination of software and hardware as described herein or their equivalent. Thus, the methods 600 , 601 and 603 described herein can be deployed as process software in the context of a computer system or data-processing system as that depicted in FIGS. 1-3 and the virtual keyboard apparatus 400 and small input device 500 respectively illustrated in FIG. 4-5 .
A preferred implementation of methods 600 , 601 and 603 generally includes two key areas for providing the virtual keyboard apparatus 400 described above. The first area involves operations generally required for keyboard layout. Such operations can include, but are not limited, to layout and application specific layout operations. The second area for providing the virtual keyboard apparatus 400 involves keyboard optimization. Thus, as indicated at block 602 , the process begins.
Keyboard Layout
Configuration
As indicated at block 604 , upon keyboard invocation (e.g., touch screen), an operation can be initiated in which keys are placed on the screen as previously described based on a particular default layout, as indicated thereafter at block 606 . If the user has performed manual augmentations to the layout, as illustrated at block 608 , those settings are retained as indicated at block 610 , and the layout is affected accordingly and the operations continue. If the user had not performed manual augmentations to the layout then the process continues without such manual augmentations. Additionally, if the keyboard optimization component has modified the layout, as depicted at block 612 , those settings can be retained and keys laid out according to the optimization component as indicated at block 614 . The process then continues, as indicated by continuation block 616 .
Embodiments may vary, but in general user requested augmentations should take precedence over automatic keyboard optimizations. A user may opt to disable optimization mutations on a per application basis and may still manually configure the key layout. A user may also desire to disable the optimization feature in several applications. For example, in a gaming application the user may only need a limited number of keys and expect certain keys to be in specific locations for input.
Layout
After acquiring the proper configuration, the keys of virtual keyboard apparatus 400 can be located in a circular fashion radiating outward from the central space button or key 410 as depicted at block 618 in FIG. 7 . Unless prevented by user augmentation, the most commonly used keys are placed closest to the center and the less commonly used keys are placed towards the edge of the keyboard as indicated at block 620 . Embodiments may vary, but in the preferred embodiment, the shift and other modifier keys are preferably placed in the corners as indicated at block 622 and as described earlier. Following the operation depicted at block 622 , an operation can be processed for determining if a touch screen is being utilized as indicated at block 624 . In touch screen devices with one screen for input and display, when a keyboard is required, the keyboard can be rendered onto the screen as indicated thereafter at block 626 , leaving enough room for textual display and the keys activated for textual input.
Application Specific Layout
Each application may have a specific layout. For example, a portable HTML editing program may include a different optimal key layout compared to that of a chat client. In the preferred embodiment, as the user switches applications the keyboard layout may switch to an optimized layout for that application as indicated respectively at blocks 628 and 630 . The user may, however, modify the layout for individual applications and the optimization component may optimize the layouts for each application. The process then continues, as indicated at block 632
Keyboard Optimization
Keyboard optimization is illustrated by the method 603 depicted in FIG. 8 . As the user enters text, their key usage can be recorded and placed in a data storage location as indicated at block 634 . Keystroke analytics for each application can be used to derive the individual user's most used keys for each potential application specific keyboard layout as depicted at blocks 636 and 638 . The analytics may vary by embodiments, but most embodiments should detect the most frequently used keys, and the most frequently used key combinations as illustrated thereafter at block 640 . Keys and key combinations used more often should be placed closer to the center of the keyboard as described at block 642 . For example, a common key combination in a document writing program may be “t-h-e”, and as such those keys should be placed close to the center of the keyboard. In the preferred embodiment a user may enable or disabled the keyboard optimization component. The process can then terminate, as depicted at block 644 .
It will be appreciated that variations of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims. | A method, apparatus and computer-usable medium for implementing a virtual keyboard for use with small input devices. A circular keyboard can be graphically displayed, in response to a user input by a user via a small input device. A circular and centrally located key can be graphically located and displayed within the center of the circular keyboard, wherein character keys radiate outward from the centrally located key (i.e., the “central key”). Character keys that are most commonly utilized by the user are preferably located closed to the circular and centrally located key within the circular keyboard. Character keys least commonly utilized by the user are preferably located at the edges of the keyboard, thereby permitting the circular keyboard to function as a self-adapting virtual keyboard for use with small input devices based on the usage of the keyboard by the user. | 27,859 |
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to an improved data processing system and, in particular, to a method and system for data processing system reliability, and more specifically, for digital logic testing.
2. Description of Related Art
As computers become more sophisticated, diagnostic and repair processes have become more complicated and require more time to complete. A service engineer may “chase” errors through lengthy diagnostic procedures in an attempt to locate one or more components that may be causing errors within the computer. For example, a diagnostic procedure may indicate an installed component or field replaceable unit (FRU) that is a likely candidate for the error, and the installed FRU may be replaced with a new FRU. The reported problem may be considered resolved at that point. If, after further testing of the previously installed FRU, the FRU is later determined to be reliable, the original problem has not actually been resolved and may remain unresolved until the next error is reported. In addition to paying for unnecessary components, a business must also pay for the recurring labor costs of the service engineer and lost productivity of the user of the error-prone system.
Diagnosing errors during initial program load (IPL) is especially difficult because the operating system, which may contain sophisticated error logging functions, has not yet been loaded at that stage of system initialization, and the IPL code is purposefully devoid of many diagnostic functions in order to keep the IPL code efficient. Many computer systems employ chipsets designed with built-in self-tests (BISTs). The BISTs are dedicated test circuits integrated with other circuitry on a chip. During power-on reset (POR) of the system, POR BISTs automatically start and complete within a few seconds. As a result, a bit signature, or binary data pattern, is generated by the BIST. The IPL code reads the POR BIST signatures and compares the generated BIST signatures with predetermined signatures stored in the IPL code during code compilation, i.e. hardcoded into the IPL code. In addition to the POR BIST, the IPL code may initiate logical BISTs (LBISTs) or array BISTs (ABISTs) and verify their signatures.
A problem may arise when there is a need to update one of the system chipsets with a newer version. When a new chipset is deployed, any IPL code containing associated BIST signatures must be updated to reflect the BIST signatures for the new chips. For most systems, the IPL code is stored in a flash module on the native I/O (NIO) planar. If there is a problem during the flash update of the IPL code that corrupts the IPL code, then the NIO planar must be replaced. If the chipset that needs to be upgraded or parts of the chipset that become defective are on different planars then the NIO planar is on a different planar than the NIO planar, then multiple planars may be replaced. In either case, replacement of a flash module results in increased costs and downtimes.
Therefore, it would be advantageous to provide a method and apparatus for efficiently storing BIST signatures within a data processing system other than in the IPL module.
SUMMARY OF THE INVENTION
A method and apparatus for storing and using chipset built-in self-test (BIST) signatures is provided. A BIST for a chip in a data processing system may be initiated by a power-on-reset in the data processing system. The BIST signature generated during the BIST is compared with a predetermined BIST signature stored in a vital products data (VPD) module associated with the chip is read. A difference between the generated BIST signature and the predetermined BIST signature is then reported.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
FIG. 1 is a pictorial representation depicting a data processing system in which the present invention may be implemented;
FIG. 2A is a block diagram depicting a typical organization of internal components in a data processing system;
FIG. 2B is a block diagram depicting an organization of internal components in a data processing system in accordance with a preferred embodiment of the present invention; and
FIG. 3 is a flowchart depicting a process by which IPL code verifies BIST signatures in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to FIG. 1, a pictorial representation depicts a data processing system in which the present invention may be implemented. A computer 100 is depicted, which includes a system unit 110 , a video display terminal 102 , a keyboard 104 , storage devices 108 , which may include floppy drives and other types of permanent and removable storage media, and mouse 106 . Additional input devices may be included with computer 100 . Computer 100 can be implemented using any suitable computer, for example, an IBM RISC/System 6000 system, a product of International Business Machines Corporation in Armonk, N.Y., running the Advanced Interactive Executive (AIX) operating system, also a product of IBM. Although the depicted representation shows a server-type computer, other embodiments of the present invention may be implemented in other types of data processing systems, such as workstations, network computers, Web-based television set-top boxes, Internet appliances, etc. Computer 100 also preferably includes a graphical user interface that may be implemented by means of system software residing in computer readable media in operation within computer 100 .
FIG. 1 is intended as an example and not as an architectural limitation for the present invention.
With reference now to FIG. 2A, a block diagram depicts a typical organization of internal components in a data processing system. Data processing system 200 employs a variety of bus structures and protocols. Although the depicted example employs a PCI bus, an ISA bus, a 6XX bus, and an inter-integrated circuit (I 2 C) bus, other bus architectures and protocols may be used. I 2 C is a simple two wire serial communications bus that employs an open collector to dot-and several ICs onto a bus. The 2 signals are serial clock line (SCL) and serial data line (SDL). This technology is patented by Philips Semiconductor.
Processor card 201 contains processor 202 , L2 cache 203 , and vital product data module (VPD) 204 that are connected to 6XX bus 205 . System 200 may contain a plurality of processor cards. Processor card 206 contains processor 207 , L2 cache 208 , and VPD module 209 .
6XX bus 205 supports system planar 210 that contains 6XX bridge 211 and memory controller/cache 212 that supports memory card 213 . System planar 210 also has a unique vital product data module, VPD 214 . Memory card 213 contains local memory 214 consisting of a plurality of dual in-line memory modules (DIMMs) 215 and 216 . Each DIMM contains its own VPD module, such as VPDs 217 and 218 . In addition, memory card 213 also has unique VPD 219 .
6XX bridge 211 connects to PCI bridges 220 and 221 via system bus 222 . PCI bridges 220 and 221 are contained on native I/O (NIO) planar 223 which supports a variety of I/O components and interfaces. PCI bridge 221 provides connections for external data streams through network adapter 224 and a number of card slots 225 - 226 via PCI bus 227 . PCI bridge 220 connects a variety of I/O devices via PCI bus 228 . Hard disk 229 may be connected to SCSI host adapter 230 , which is connected to PCI bus 228 . Graphics adapter 231 may also be connected to PCI bus 228 as depicted, either directly or indirectly.
ISA bridge 232 connects to PCI bridge 220 via PCI bus 228 . ISA bridge 232 provides interconnection capabilities through NIO controller 233 via ISA bus 234 , such as serial connections 235 and 236 . Floppy drive connection 237 provides removable storage. Keyboard connection 238 and mouse connection 239 allow data processing system 200 to accept input data from a user. Non-volatile RAM (NVRAM) 240 provides non-volatile memory for preserving certain types of data from system disruptions or system failures, such as power supply problems. System firmware 241 is also connected to ISA bus 234 and controls the initial BIOS using initial program load (IPL) code 242 containing hard-coded built-in self-test (BIST) signatures 243 . Service processor 244 is connected to ISA bus 234 and provides functionality for system diagnostics or system servicing.
Service processor 244 detects errors and passes information to the operating system. The source of the errors may or may not be known to a reasonable certainty at the time that the error is detected. The operating system may merely log the errors against the system planar.
For example, boot-time errors, severe intermittent problems, and adverse environmental computing conditions, such as conditional bandwidth bottlenecks, may be logged by the service processor into an error report buffer. These errors are eventually output and reported in some form, either to a hard drive or one of many types of backup systems. Each detected error may result in the generation of an error record comprising a timestamp at the time of detection, detailed data pertinent to the failing function, including physical location code, symptom bits, etc. Further analysis may be done at a later time if the error logs are stored in an error log file or error log buffer containing the data that some problem determination procedures may require for analysis.
The manner of logging and processing a detected error may depend on the type of error and when the error occurs, e.g., whether the error occurs during system initialization procedures. If an error is detected during system initialization, all devices, components, or services within the data processing system may not have been initialized. For example, if an error is detected during system initialization, the service firmware may present certain errors to a system operator by writing error codes or error messages to an LCD display or system display monitor physically connected to the data processing system without being able to log error-derived data to the system log file. In other cases, the action of logging the data may start problem determination procedures in the operating system automatically. This may be accomplished by a deamon within the operating system that invokes pre-registered procedures based on the personality traits of the error logged.
NIO planar 223 also contains unique VPD module 245 . Service processor 244 may read VPD modules 204 , 209 , 214 , 217 - 219 , and 245 via I 2 C bus 299 . The vital product data modules contain configuration information, such as product serial numbers, location of manufacturing, engineering change (EC) level data, FRU number, and part numbers that describe associated chips, boards, parts, etc. Other VPD information may include the speed, size, or other operational parameters of associated modules. Some of the VPD information in the VPD module may be written into the VPD module in a write-protected manner by a manufacturer just prior to completion and shipping of a product. Other VPD modules may be implemented within system 200 , such as a VPD module within network adapter 224 .
Those of ordinary skill in the art will appreciate that the hardware in FIG. 2A may vary depending on the system implementation. For example, the system may have more processors, and other peripheral devices may be used in addition to or in place of the hardware depicted in FIG. 2 A. The depicted examples are not meant to imply architectural limitations with respect to the present invention.
With reference now to FIG. 2B, a block diagram depicts an organization of internal components in a data processing system in accordance with a preferred embodiment of the present invention. Similar reference numerals refer to similar components in FIG. 2 A and FIG. 2 B. However, VPD modules 204 , 209 , 214 , 217 - 219 , and 245 in FIG. 2A have been replaced in FIG. 2B with VPD′ modules 290 - 296 , and IPL code 298 in FIG. 2A has been replaced with IPL code 299 in FIG. 2 B. Service processor 244 may still access VPD′ modules 290 - 296 via I 2 C bus 299 in which the VPD′ modules contain BIST signatures.
By storing the chipset BIST signatures, such as POS BIST, LBIST, and ABIST signatures, in the VPD′ modules associated with the chipset, such as in VPD modules 290 - 296 , the IPL code can compare the chip BIST signatures that are generated during BISTs with the correct BIST signatures stored in the VPD modules rather than relying on a hard-coded BIST signature stored in the IPL code or system firmware. When the need arises to replace a planar with a newer chipset, the VPD′ modules 290 - 296 will be preconfigured with the new BIST signature for the new chipset. The present invention eliminates the need to modify the IPL code or perform a flash update for the new IPL code, which may corrupt the IPL code.
With reference now to FIG. 3, a flowchart depicts a process by which IPL code verifies BIST signatures in accordance with a preferred embodiment of the present invention. The process begins with the power-on-reset initiating a BIST for a chip (step 302 ). The IPL code reads the BIST signature generated during the BIST, (step 304 ), and the IPL code also reads the predetermined, correct BIST signature stored in the VPD module associated with the chip (step 306 ). A determination is then made as to whether the generated BIST signature and the stored BIST signature are equal (step 308 ). If so, the IPL code continues with other boot functions. If not, then the BIST discrepancy is reported in an appropriate manner (step 310 ). The process is then complete with respect to initializing the chip.
The advantages provided by the present invention should be apparent in view of the detailed description of the invention provided above. By storing BIST signatures in VPD modules, the need for potentially problematic updates of IPL code is eliminated, thereby saving repair cost and system downtime.
It is important to note that while the present invention has been described in the context of a fully functioning data processing system, those of ordinary skill in the art will appreciate that the processes of the present invention are capable of being distributed in the form of a computer readable medium of instructions and a variety of forms and that the present invention applies equally regardless of the particular type of signal bearing media actually used to carry out the distribution. Examples of computer readable media include ROM chips or writable-type media such a floppy disc, a hard disk drive, a RAM, and CD-ROMs as well as transmission-type media such as digital and analog communications links.
The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiment was chosen and described in order to best explain the principles of the invention, the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated. | A method and apparatus for storing and using chipset built-in self-test (BIST) signatures is provided. A BIST for a chip in a data processing system may be initiated by a power-on-reset in the data processing system. The BIST signature generated during the BIST is compared with a predetermined BIST signature stored in a vital products data (VPD) module associated with the chip is read. A difference between the generated BIST signature and the predetermined BIST signature is then reported. | 16,134 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims priority under the International Convention of German Utility Model Application No. G 94 13 334.4, filed Aug. 18, 1994, the disclosure of which is incorporated herein by reference for all purposes.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to buffet platters, and more particularly to stackable buffet platters.
2. Description of the Prior Art
Buffet platters for making up buffet meals are in common use in the catering trade, the known buffet planers consisting of a six or more sided plastic frame, which is assembled from six or more identical individual segments. These individual segments are screwed together, hidden on the inside. A mirror about four millimeters thick is clamped in the frame made up from the individual segments, a groove being cut in the inner side of the individual frame segments, in which groove the mirror is fitted and clamped by the screwing together of the individual segments. The upper and lower edges of these individual segments are so profiled that they prevent sideways slipping when stacking one on the other. These plastics frames have a frame height of about ten centimeters, so that the buffet platters can be stacked even with food served up on the mirror. However this construction has several disadvantages.
Firstly, relative expensive manufacture results from the multi-part design with the individual segments, since the screw connections have to be made separately in the frame, which leads to substantial additional expense, especially with twelve or sixteen sided designs. Moreover round or oval basic shapes of the buffet platter can hardly be produced in this way. Secondly, a relatively small torsional strength results from the screwed construction, so that the clamped-in mirror can easily break with stronger one-sided loading. In addition, the mirror of the glass plate must be made as a food-carrying plate with a relatively large wall thickness, in order to be able to carry the served up food and provide sufficient stiffness even with twisting. However, this makes the buffet platter relatively heavy and thus awkward to handle. Furthermore, a particular disadvantage is that, because of the mirror clamped in the individual segments, juices or marinades can run into the clamping groove from the served up food, so that, for reasons of hygiene, the buffet platter has to be completely disassembled and thoroughly cleaned after practically every serving.
SUMMARY OF THE INVENTION
The present invention avoids the aforementioned disadvantages of the prior art with a buffet platter that is simple to make, is light in weight, and which is highly stable during use.
Particularly simple manufacture results from the formation of the buffet platter in one piece, since its plastics frame can preferably be made as a deep drawn part in one working step. Thus, the manufacture of screw bores, threaded bushes and assembly of the individual segments are no longer necessary. In addition, this buffet platter has enhanced stability on account of the one-piece structure, so that the wall thickness can also be reduced and the overall weight of the buffet platter be reduced. A particular advantage is that the food-carrying plate is supported by a base surface formed in one piece with the plastics frame. This firstly results in additional stiffening of the plastics frame and secondly provides direct support for the food-carrying plate, so that this mirror or glass plate can also be made with a very small wail thickness. The wall strength or thickness of the food-carrying plate can even be reduced to a foil thickness, since the smooth surface is supported by the base surface. This results in further reduction of the total weight of the buffet planer, so that in all very good handiness is obtained. It is further of particular advantage that the food-carrying plate no longer has to be clamped in the plastics frame, because of the continuous support on the base surface, but can be placed directly on the frame, whereby the grooves at the edge of the buffet platter which demand so much cleaning are avoided.
It is further advantageous that, on account of the small wall thickness of the plastics frame, provision of a parking edge by the raised profiling of the plastics frame cooperating with the lower edge of the buffet platter stacked thereon, gives security against sideways slipping, without the underside having to have additional profiling worked thereon. This results in reliable centring of the buffet platters stacked on top of each other, so that relatively high stacks can be made up for serving or catering purposes.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the buffet platter will now be described in more detail and explained with reference to the drawings, in which:
FIG. 1 is a plan view of a buffet platter with a six-sided basic shape;
FIG. 2 is a side view of the buffet platter according to FIG. 1 in half section, with a schematic representation of stacking;
FIG. 3 shows an enlarged edge region of the buffet platter according to FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A buffet platter 1 is shown in FIG. 1, with a six-sided basic shape, the buffet platter 1 being formed essentially by a likewise six-sided plastics frame 2 and a food-carrying plate 3 placed thereon for serving foodstuffs. There is a raised profiling 4 surrounding the outer edge of the plastics frame 2, so that when placing several buffet platters 1 one on top of the other (cf. FIG. 2), the profiling 4 is engaged by the respective bottom edge la of the buffet platter 1, wherein a narrow parking edge 4a of the plastics frame 2 is provided adjacent the surrounding profiling 4 as a transition to the outer periphery of the plastics frame 2, on which edge 4a the bottom edge 1a bears.
In accordance with the novelty, the plastics frame 2 of the buffet platter 1 is provided with a base surface 5, on which the food-carrying plate 3, preferably a mirrored glass plate, lies and is thus supported. The plastics frame 2 is preferably formed from a plastics plate as a deep drawn part, so that the shape shown in half section in FIG. 2 results. It is important that arbitrary shapes, for example semicircular or oval shapes can be formed in a simple way by suitable design of the deep drawing tool, because of the formation of the plastics frame 2 in one piece. The food-carrying plate 3 is at least for the most part supported by the base surface 5, this base surface 5 being reined continuously in general. However openings 6, recesses and/or hollows can be formed or pressed in the base surface 5 in the deep drawing operation, so that there is a further reduction in weight and an increase in the stiffness of form of the plastics frame 2. It should be noted that, in contrast to the known buffet platter with a plastics frame consisting of a plurality of individual segments, each side is connected through the base surface 5 to the opposed side of the plastics frame 2 by virtue of the one-piece design of the plastics frame 2, so that a construction which is particularly torsionally stiff results. Handles 9 or gripping recesses can be formed directly on the plastics frame 2, so that the buffet platter 1 can be carried easily.
The buffet platter 1 according to FIG. 1 is shown in half section in FIG. 2, from which the direct bearing and wide-area support of the food-carrying plate 3 by the base surface 5 is in particular apparent. It should be mentioned that, on account of this support by means of the base surface 5, the food-carrying plate 3 can be made relatively thin and can even only have a wall thickness like that of a foil. The food-carrying plate 3 can also be in the form of a transparent glass plate, so that the base surface 5 can also serve as a display plate by virtue of its recessed form, for example through a hollow 6' shown in broken lines, in which hollow 6' decorations, for example flowers, can be placed. The hollow 6' can also be accessible by a drawer or a screw cover. Partial silvering of the food-carrying plate 3 is also possible, in which the annular region of the food-carrying plate 3 which lies on the base surface 5 is silvered, while the central region over the, hollow 6' or the opening 6 is transparent, in order to leave the view clear to the decoration or a business logo.
In order to increase the sideways security against slipping with a plurality of buffet platters 1, 1', 1", etc. stacked on each other as shown in FIG. 2, plurality of clips 10 can be provided on the inner periphery of the plastics frame 2, having an offset part engaging the profiling 4 of the buffet platter 1' stacked thereunder from the inside. Thus, in addition to the engagement of the lower edge 1a with the profiling 4 from the outside, there is a further engagement from the inside, as is shown especially in FIG. 3 in an enlargement of the corner region B. It should be mentioned that these clips could be stuck on to the inner periphery of the plastics frame 2 but also in implementation with only two clips 10, they can be screwed on at the same time as the handles 9, as is shown in FIG. 3. As can be seen from FIG. 2, when the buffet platter 1 is placed on the buffet platter 1' stacked thereunder, the lower edge 1a engages the profiling 4 from the outside and the clips 10 engage the profiling 4 from the inside, so that a particularly stable stack results from stacking a plurality of buffet platters in accordance with the arrow A. As is further apparent, by stacking a plurality of buffet platters 1, 1', 1", etc. on one another, a hollow space is created in each case, so that prepared meals can be kept dust-tight and be transported.
The region B indicated by a circle in FIG. 2 is shown enlarged and in cross section in FIG. 3. From this can be seen in particular the relatively thin-walled design of the plastics frame 2, the raised form of the profiling 4 and the support of the food-carrying plate 3 by the base surface 5, In order to increase the stiffness of the shape, raised parts 7 in the form of webs, ribs or pips can also be provided on the base surface 5, which also results in the food-carrying plate 3 resting at points. In order to reduce the weight, stamped out pans or openings 6 can be provided in the base surface 5, without the load-beating capacity of the base surface 5 being substantially reduced. The food-carrying plate 3 is stuck on to the base surface 5 in order to fix it inside the plastics frame 2, preferably by spot application of adhesive, as is known in fixng tiles for example. The gap resulting at the edge region of the food-carrying plate 3 relative to the plastics frame 2 and its profiling 4 is filled with a jointing material 8 impervious to foodstuffs, in order to avoid leakage of food juices, sauces and the like here, as well as to facilitate cleaning. Irregularities in the cutting of the food-carrying plate by the glassworks can also be compensated for by this jointing material 8, preferably a silicone, so that, in contrast to the known buffet platter the food-carrying plate 3 does not have to be cut particularly accurately out of mirror glass.
In the side region of FIG. 3 there is moreover shown the fixing of the handle 9, in which its yoke is merely stuck through the plastics frame 2 and screwed up by a cap nut. The offset clips 10 can be fixed at the same time by means of aligned bores. The underside of the clips 10 then fits from the inside round the profiling 4 of the next buffet platter thereunder in the superimposed state. In general two or three such clips 10 suffice for this additional security against slipping by internal engagement, as is shown for example in FIG. 1 in hidden, broken lines.
Although a six-sided buffet platter 1 is here shown in FIGS. 1 and 2, the plastics frame 2 and correspondingly the food-carrying plate 3 can have any arbitrary basic shape, especially a circular or oval shape, as is often desired for buffet serving of dishes. Six, eight or twelve-sided shapes can also be made simply. After making the one-piece plastics frame 2 by forming of a unitary plastics sheet, preferably by deep drawing a unitary or one-piece plastics plate, the food-carrying plate 3 is cut according to the basic shape of the plastics frame 2 and laid on the base surface 5 and stuck on. It is important that the food-carrying plate 3 is held without stress within the plastics frame 2 and is no longer clamped in, in contrast to the state of the art. This reduces the danger of breakage substantially, since there are not stresses in the food-carrying plate 3. Because of this the novel buffet platter 1 can even drop from small heights without breaking. Furthermore the food-carrying plate 3 can also consist of very thin glass or even of mirrored metal foil or an electro-deposited metal layer, since the support function is taken over by the base surface 5. This results in a substantial saving in weight and thus easier handling in transport and in making up the buffet.
While this invention has been described in terms of several preferred embodiments, it is contemplated that alterations, permutations, and equivalents thereof will become apparent to those skilled in the art after studying preceding descriptions and the drawing. It is therefore intended that the following appended claims be interpreted to include all such alterations, permutations, and equivalents as fall within the true spirit and scope of the present invention. | A buffet platter with a plastic frame for maintaining the space between buffet platters stacked on each other has a smooth-surfaced, preferably mirrored, food-carrying plate at the upper side is surrounded by the plastic frame, which is profiled at the outer edge to engage with a buffet platter of the same design stacked thereon, in order to prevent sideways slipping. The plastic frame is formed in one piece and the food-carrying plate is supported on a base surface of the plastic frame that is formed in one piece with the plastics frame. | 13,778 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 12/185,425, filed Aug. 4, 2008, now U.S. Pat. No. 8,148,699, issued Apr. 3, 2012, which is a continuation of U.S. patent application Ser. No. 11/078,706, filed Mar. 14, 2005, now U.S. Pat. No. 7,408,174, issued Aug. 5, 2008, which claims the benefit under 35 U.S.C. §119(e) of provisional patent application Ser. No. 60/552,185 filed on Mar. 12, 2004 and Ser. No. 60/613,215 filed on Sep. 28, 2004, the contents of each of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
In one of its aspects, the present invention relates to a fluid treatment system, more particularly, an ultraviolet radiation water treatment system. In another of its aspects, the present invention relates to a method for treating a fluid, more particularly a method for irradiating water.
2. Description of the Prior Art
Fluid treatment systems are generally known in the art. More particularly, ultraviolet (UV) radiation fluid treatment systems are generally known in the art. Early treatment systems comprised a fully enclosed chamber design containing one or more radiation (preferably UV) lamps. Certain problems existed with these earlier designs. These problems were manifested particularly when applied to large open flow treatment systems which are typical of larger scale municipal waste water or potable water treatment plants. Thus, these types of reactors had associated with them the following problems:
relatively high capital cost of reactor;
difficult accessibility to submerged reactor and/or wetted equipment (lamps, sleeve cleaners, etc);
difficulties associated with removal of fouling materials from fluid treatment equipment;
relatively low fluid disinfection efficiency, and/or
full redundancy of equipment was required for maintenance of wetted components (sleeves, lamps and the like).
The shortcomings in conventional closed reactors led to the development of the so-called “open channel” reactors.
For example, U.S. Pat. Nos. 4,482,809, 4,872,980 and 5,006,244 (all in the name of Maarschalkerweerd and all assigned to the assignee of the present invention and hereinafter referred to as the Maarschalkerweerd #1 Patents) all describe gravity fed fluid treatment systems which employ ultraviolet (UV) radiation.
Such systems include an array of UV lamp modules (e.g., frames) which include several UV lamps each of which are mounted within sleeves which extend between and are supported by a pair of legs which are attached to a cross-piece. The so-supported sleeves (containing the UV lamps) are immersed into a fluid to be treated which is then irradiated as required. The amount of radiation to which the fluid is exposed is determined by the proximity of the fluid to the lamps, the output wattage of the lamps and the flow rate of the fluid past the lamps. Typically, one or more UV sensors may be employed to monitor the UV output of the lamps and the fluid level is typically controlled, to some extent, downstream of the treatment device by means of level gates or the like.
The Maarschalkerweerd #1 Patents teach fluid treatment systems which were characterized by improved ability to extract the equipment from a wetted or submerged state without the need for full equipment redundancy. These designs compartmentalized the lamp arrays into rows and/or columns and were characterized by having the top of the reactor open to provide free-surface flow of fluid in a “top open” channel.
The fluid treatment system taught in the Maarschalkerweerd #1 Patents is characterized by having a free-surface flow of fluid (typically the top fluid surface was not purposely controlled or constrained). Thus, the systems would typically follow the behavior of open channel hydraulics. Since the design of the system inherently comprised a free-surface flow of fluid, there were constraints on the maximum flow each lamp or lamp array could handle before either one or other hydraulically adjoined arrays would be adversely affected by changes in water elevation. At higher flows or significant changes in the flow, the unrestrained or free-surface flow of fluid would be allowed to change the treatment volume and cross-sectional shape of the fluid flow, thereby rendering the reactor relatively ineffective. Provided that the power to each lamp in the array was relatively low, the subsequent fluid flow per lamp would be relatively low. The concept of a fully open channel fluid treatment system would suffice in these lower lamp power and subsequently lower hydraulically loaded treatment systems. The problem here was that, with less powerful lamps, a relatively large number of lamps was required to treat the same volume of fluid flow. Thus, the inherent cost of the system would be unduly large and/or not competitive with the additional features of automatic lamp sleeve cleaning and large fluid volume treatment systems.
This led to the so-called “semi-enclosed” fluid treatment systems.
U.S. Pat. Nos. 5,418,370, 5,539,210 and Re36,896 (all in the name of Maarschalkerweerd and all assigned to the assignee of the present invention and hereinafter referred to as the Maarschalkerweerd #2 patents) all describe an improved radiation source module for use in gravity fed fluid treatment systems which employ UV radiation. Generally, the improved radiation source module comprises a radiation source assembly (typically comprising a radiation source and a protective (e.g., quartz) sleeve) sealingly cantilevered from a support member. The support member may further comprise appropriate means to secure the radiation source module in the gravity fed fluid treatment system.
Thus, in order to address the problem of having a large number of lamps and the incremental high cost of cleaning associated with each lamp, higher output lamps were applied for UV fluid treatment. The result was that the number of lamps and subsequent length of each lamp was dramatically reduced. This led to commercial affordability of automatic lamp sleeve cleaning equipment, reduced space requirements for the treatment system and other benefits. In order to use the more powerful lamps (e.g. medium pressure UV lamps), the hydraulic loading per lamp during use of the system would be increased to an extent that the treatment volume/cross-sectional area of the fluid in the reactor would significantly change if the reactor surface was not confined on all surfaces, and hence such a system would be rendered relatively ineffective. Thus, the Maarschalkerweerd #2 patents are characterized by having a closed surface confining the fluid being treated in the treatment area of the reactor. This closed treatment system had open ends which, in effect, were disposed in an open channel. The submerged or wetted equipment (UV lamps, cleaners and the like) could be extracted using pivoted hinges, sliders and various other devices allowing removal of equipment from the semi-enclosed reactor to the free surfaces.
The fluid treatment system described in the Maarschalkerweerd #2 patents was typically characterized by relatively short length lamps which were cantilevered to a substantially vertical support arm (i.e., the lamps were supported at one end only). This allowed for pivoting or other extraction of the lamp from the semi-enclosed reactor. These significantly shorter and more powerful lamps inherently are characterized by being less efficient in converting electrical energy to UV energy. The cost associated with the equipment necessary to physically access and support these lamps was significant.
Historically, the fluid treatment modules and systems described in the Maarschalkerweerd #1 and #2 patents have found widespread application in the field of municipal waste water treatment (i.e., treatment of water that is discharged to a river, pond, lake or other such receiving stream).
In the field of municipal drinking water, it is known to utilize so-called “closed” fluid treatment systems or “pressurized” fluid treatment systems.
Closed fluid treatment devices are known—see, for example, U.S. Pat. No. 5,504,335 (Maarschalkerweerd #3). Maarschalkerweerd #3 teaches a closed fluid treatment device comprising a housing for receiving a flow of fluid. The housing comprises a fluid inlet, a fluid outlet, a fluid treatment zone disposed between the fluid inlet and the fluid outlet, and at least one radiation source module disposed in the fluid treatment zone. The fluid inlet, the fluid outlet and the fluid treatment zone are in a collinear relationship with respect to one another. The at least one radiation source module comprises a radiation source sealably connected to a leg which is sealably mounted to the housing. The radiation source is disposed substantially parallel to the flow of fluid. The radiation source module is removable through an aperture provided in the housing intermediate to fluid inlet and the fluid outlet thereby obviating the need to physically remove the device for service of the radiation source.
U.S. Pat. No. 6,500,346 [Taghipour et al. (Taghipour)] also teaches a closed fluid treatment device, particularly useful for ultraviolet radiation treatment of fluids such as water. The device comprises a housing for receiving a flow of fluid. The housing has a fluid inlet, a fluid outlet, a fluid treatment zone disposed between the fluid inlet and the fluid outlet and at least one radiation source having a longitudinal axis disposed in the fluid treatment zone substantially transverse to a direction of the flow of fluid through the housing. The fluid inlet, the fluid outlet and the fluid treatment zone are arranged substantially collinearly with respect to one another. The fluid inlet has a first opening having: (i) a cross-sectional area less than a cross-sectional area of the fluid treatment zone, and (ii) a largest diameter substantially parallel to the longitudinal axis of the at least one radiation source assembly.
Practical implementation of known fluid treatment systems of the type described above have been such that the longitudinal axis of the radiation source is: (i) parallel to the direction of fluid flow through the fluid treatment system, or (ii) orthogonal to the direction of fluid flow through the fluid treatment system. Further, in arrangement (ii), it has been common to place the lamps in an array such that, from an upstream end to a downstream end of the fluid treatment system, a downstream radiation source is placed directly behind an upstream radiation source.
The use of arrangement (ii) in an UV radiation water treatment system has been based on the theory that radiation was effective up to a prescribed distance from the radiation source, depending on the transmittance of the water being treated. Thus, it has become commonplace to interspace the radiation sources in arrangement (ii) such that the longitudinal axes of adjacent radiation sources are spaced at a distance equal to approximately twice the prescribed distance mentioned in the previous sentence.
Unfortunately, for the treatment of large volumes of fluid, arrangement (ii) can be disadvantageous for a number of reasons. Specifically, implementation of arrangement (ii) requires a relatively large “footprint” or space to house the radiation sources. Further, the use of a large number of radiation sources in arrangement (ii) creates a relatively large coefficient of drag resulting in a relatively large hydraulic pressure loss/gradient over the length of the fluid treatment system. Still further, the use of a large number of radiation sources in arrangement (ii) can produce vortex effects (these effects are discussed in more detail hereinbelow) resulting in forced oscillation of the radiation sources—such forced oscillation increases the likelihood of breakage of the radiation source and/or protective sleeve (if present).
Accordingly, there remains a need in the art for a fluid treatment system, particularly a closed fluid treatment system which has one or more of the following features:
it can treat large volumes of fluid (e.g., wastewater or drinking water and the like);
it can increase the limit of the maximum admissible velocity through the reactor;
it requires a relatively small “footprint”;
it results in a relatively lower coefficient of drag resulting in an improved hydraulic pressure loss/gradient over the length of the fluid treatment system;
it results in relatively lower (or no) forced oscillation of the radiation sources thereby obviating or mitigating breakage of the radiation source and/or protective sleeve (if present);
it can be readily adapted to make use of relatively recently developed so-called “low pressure high output” (LPHO), amalgam and/or other UV emitting lamps while allowing for ready extraction of the lamps from the fluid treatment system for servicing and the like;
it can employ a lamp of a standard length for varying widths of reactors;
it can be readily combined with a cleaning system for removing fouling materials from the exterior of the radiation source(s);
it can be readily installed in a retrofit manner in an existing fluid treatment plant; and
it provides relatively improved disinfection performance compared to conventional fluid treatment systems.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a novel fluid treatment system which obviates or mitigates at least one of the above-mentioned disadvantages of the prior art.
In one of its aspects, the present invention relates to a fluid treatment system comprising:
an inlet;
an outlet;
a fluid treatment zone disposed between the inlet and the outlet, the fluid treatment zone having disposed therein: (i) an elongate first radiation source assembly having a first longitudinal axis, and (ii) an elongate second radiation source assembly having a second longitudinal axis;
wherein the first longitudinal axis and the second longitudinal axis are non-parallel to each other and to a direction of fluid flow through the fluid treatment zone.
In another of its aspects, the present invention relates to a fluid treatment system comprising:
an inlet;
an outlet;
a fluid treatment zone disposed between the inlet and the outlet, the fluid treatment zone having disposed therein an array of radiation source assemblies arranged serially from an upstream region to a downstream region of fluid treatment zone such that: (i) each radiation source assembly has a longitudinal axis transverse to a direction of fluid flow through the fluid treatment zone, (ii) the longitudinal axis of an upstream radiation source assembly is staggered with respect to a downstream radiation source assembly in a direction orthogonal to the direction of fluid flow through the fluid treatment zone to define a partial overlap between the upstream radiation source assembly and the downstream radiation source assembly, and (iii) a flow of fluid has no unobstructed path through the fluid treatment zone.
In another of its aspects, the present invention relates to a fluid treatment system comprising:
an inlet;
an outlet;
a fluid treatment zone disposed between the inlet and the outlet, the fluid treatment zone having disposed therein an array of rows of radiation source assemblies;
each radiation source assembly having a longitudinal axis transverse or parallel to a direction of fluid flow through the fluid treatment zone;
each row comprising a plurality of radiation source assemblies in spaced relation in a direction transverse to the direction of fluid flow through the fluid treatment zone to define a gap through which fluid may flow between an adjacent pair of radiation source assemblies;
all rows in the array being staggered with respect to one another in a direction orthogonal to the direction of fluid flow through the fluid treatment zone such that the gap between an adjacent pair of radiation source assemblies in an upstream row of radiation source assemblies is partially or completely obstructed in the direction of fluid flow by at least two serially disposed downstream rows of radiation source assemblies.
In yet another of its aspects, the present invention relates to a fluid treatment system comprising:
an inlet;
an outlet;
a fluid treatment zone disposed between the inlet and the outlet, the fluid treatment zone having disposed therein an array of radiation source assemblies, each radiation source assembly having a longitudinal axis transverse to a direction of fluid flow through the fluid treatment zone;
the array of radiation source assemblies comprising: a first row of radiation source assemblies, a second row of radiation source assemblies downstream from the first row of radiation source assemblies, a third row of radiation source assemblies downstream from the second row of radiation source assemblies and a fourth row of radiation source assemblies downstream from the third row of radiation source assemblies;
an adjacent pair of radiation source assemblies in the first row defining a first gap through which fluid may flow, a radiation source assembly from the second row partially obstructing the first gap to divide the first gap into a second gap and a third gap, a radiation source assembly from the third row at least partially obstructing the second gap and a radiation source assembly from the fourth row at least partially obstructing the third gap.
In yet another of its aspects, the present invention relates to a fluid treatment system comprising:
an inlet;
an outlet;
a fluid treatment zone disposed between the inlet and the outlet, the fluid treatment zone having disposed therein an array comprising 4 rows radiation source assemblies arranged serially from an upstream portion to a downstream portion of the fluid treatment zone;
each radiation source assembly having a longitudinal axis transverse to a direction of fluid flow through the fluid treatment zone;
wherein: (i) a first pair of rows of radiation source assemblies in the array comprise substantially uniform spacing between adjacent pairs of radiation source assemblies in the row; and (ii) a second pair of rows of radiation source assemblies in the array comprise substantially non-uniform spacing between adjacent pairs of radiation source assemblies in the row.
In addition to the arrayed arrangement of radiation source assemblies described above, it is possible to utilize so-called boundary radiation source assemblies—i.e., radiation source assemblies placed in parallel and in close proximity to the opposed reactor walls. All axes of the boundary radiation source assemblies adjacent to one another, either of the respective outer boundary radiation source assemblies are in the same plane.
Thus, the present inventors have discovered a fluid treatment system having one or more of the following advantages:
it can treat large volumes of fluid (e.g., wastewater, drinking water or the like);
it can increase the limit of the maximum admissible velocity through the reactor;
it requires a relatively small “footprint”;
it results in a relatively lower coefficient of drag resulting in an improved hydraulic pressure loss/gradient over the length of the fluid treatment system;
it results in relatively lower (or no) forced oscillation of the radiation sources thereby obviating or mitigating of breakage of the radiation source and/or protective sleeve (if present);
it can be readily adapted to make use of low pressure ultraviolet emitting lamps and relatively recently developed so-called “low pressure high output” (LPHO), amalgam and/or other ultraviolet radiation and photon emitting lamps while allowing for ready extraction of the lamps from the fluid treatment system for servicing and the like;
it can employ a lamp of standard length for varying widths of reactors simply by varying the transverse angle between the lamps;
it can be readily combined with a cleaning system for removing fouling materials from the exterior of the radiation source(s);
it can be readily installed in a retrofit manner in an existing fluid treatment plant; and
it provides relatively improved disinfection performance compared to conventional fluid treatment systems (e.g., systems in which the radiation source is disposed such that its longitudinal axis is parallel or orthogonal to the direction of fluid flow through the fluid treatment zone contained within the system).
In one of its general aspects, the present invention relates to a fluid treatment system comprising at least two radiation source assemblies arranged in a novel manner. Specifically, the radiation source assemblies are arranged such that the respective longitudinal axes of the radiation sources therein are in a non-parallel relationship with each other and with respect to the direction of fluid flow through the fluid treatment zone. This is different than conventional fluid treatment systems wherein all lamps are arranged such that the longitudinal axes of the respective radiation sources within the radiation source assemblies are in a parallel relationship and these axes are orthogonal or parallel to the direction of fluid flow.
In a particularly preferred embodiment of this aspect of the invention, the radiation source assemblies are arranged in an array which is generally V-shaped. In this embodiment, it is preferred to have respective banks of radiation source assemblies which are stacked to form the V-shaped arrangement. As will be discussed in more detail below, one of the advantages of orienting the radiation source assemblies in this matter is a significant reduction in forced oscillation of the radiation sources due to vortex effects.
In another of its aspects, the present invention relates to a fluid treatment system wherein the radiation source assemblies are arranged transverse or parallel to the direction of fluid flow through the fluid treatment zone as a series of rows, each row comprising a plurality of radiation sources assemblies spaced apart in a direction orthogonal to the direction of fluid flow through the fluid treatment zone. In one embodiment of this aspect of the invention (also referred to as the “staggered/transverse orientation”), the radiation source assemblies are arranged transverse to the direction of fluid flow through the fluid treatment zone and oriented in a manner whereby, from an upstream portion to a downstream portion of the fluid treatment zone, the radiation source assemblies are staggered in a direction orthogonal to a direction of fluid flow through the fluid treatment zone to define partial overlap between these assemblies. Preferably, the collection of assemblies is arranged such that a flow of fluid has no unobstructed path through the arrangement of radiation source assemblies in the fluid treatment zone. Practically, one may envision this by viewing the inlet of the fluid treatment zone and seeing no clear, unobstructed path through the arrangement of radiation source assemblies in the fluid treatment zone from the inlet to the outlet. In another embodiment of this aspect of the invention (also referred to as the “staggered/parallel orientation”), the radiation source assemblies are arranged parallel to the direction of fluid flow through the arrangement of radiation source assemblies in the fluid treatment zone and oriented in a manner whereby, from an upstream portion to a downstream portion of the fluid treatment zone, the radiation source assemblies are arranged as in the form of at least two serially disposed banks such that rows of radiation source assemblies in an upstream bank are staggered with respect to rows of radiation source assemblies in a downstream bank in a direction orthogonal to the direction of fluid flow through the arrangement of radiation source assemblies in the fluid treatment zone.
In another of its aspects, the present invention relates to a fluid treatment system in which an array of radiation source assemblies are arranged in the fluid treatment zone. The radiation source assemblies are oriented transverse to the direction of fluid flow through the fluid treatment zone. The array of radiation source assemblies includes a first row of radiation source assemblies arranged to define a predetermined spacing between pairs of radiation source assemblies in the row in a direction orthogonal to the direction of fluid flow through the fluid treatment zone. At least two further rows of radiation source assemblies are disposed downstream of the first row of radiation source assemblies. In one preferred embodiment, these downstream rows of radiation source assemblies (i.e., two or more of such rows) combine to fill or occupy the pre-determined spacing between pairs of radiation source assemblies within the column of lamps in the first row—i.e., if one were to view the array of radiation source assemblies from the inlet of the fluid treatment system. In another preferred embodiment, these downstream rows of radiation source assemblies (i.e., two or more of such rows) combine only to partially fill or occupy the pre-determined spacing between pairs of radiation source assemblies within the column of lamps in the first row—i.e., if one were to view the array of radiation source assemblies from the inlet of the fluid treatment system.
In the present fluid treatment system, it is possible to incorporate a so-called transition region upstream and/or downstream of the fluid treatment zone. Preferably, such a transition region serves to funnel or otherwise transition the flow of fluid in a manner such that cross-sectional area of the flow of fluid orthogonal to the direction of fluid flow is: (i) increased (if the transition region is placed upstream of the fluid treatment zone) thereby decreasing fluid flow velocity, or (ii) decreased (if the transition region is placed downstream of the fluid treatment zone) thereby increasing fluid flow velocity.
Throughout the specification, reference is made to terms such as “closed zone”, “closed cross-section” and “constrained”. In essence, these terms are used interchangeably and are intended to encompass a structure which effectively surrounds the fluid flow in a manner similar to that described in the Maarschalkerweerd #2 patents (with particular reference to the fluid treatment zone described therein).
Further, as used throughout this specification, the term “fluid” is intended to have a broad meaning and encompasses liquids and gases. The preferred fluid for treatment with the present system is a liquid, preferably water (e.g., wastewater, industrial effluent, reuse water, potable water, ground water and the like). Still further, the terms “rows” and “columns” are used throughout this specification in relation to arrangements of radiation sources and it is to be understood that these terms are used interchangeably.
Those with skill in the art will recognize that there is reference throughout the specification to the use of seals and the like to provide a practical fluid seal between adjacent elements in the fluid treatment system. For example, those of skill in the art will recognize that it is well known in the art to use combinations of coupling nuts, O-rings, bushings and like to provide a substantially fluid tight seal between the exterior of a radiation source assembly (e.g., water) and the interior of a radiation source assembly containing the radiation source (e.g., an ultraviolet radiation lamp).
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will be described with reference to the accompanying drawings, wherein like numerals designate like elements, and in which:
FIG. 1 illustrates, in perspective view, partially cutaway, a schematic of a first embodiment of the present fluid treatment system;
FIG. 2 illustrates a perspective view, partially cutaway of a second embodiment of the present fluid treatment system;
FIG. 3 illustrates an end view from the inlet of the fluid treatment system illustrated in FIG. 2 ;
FIG. 4 illustrates a top view (partially cutaway) of the fluid treatment system illustrated in FIG. 2 ;
FIG. 5 illustrates a side elevation of the fluid treatment system illustrated in FIG. 2 ;
FIG. 6 illustrates a schematic side elevation of orientation of radiation source assemblies in a third embodiment of the present fluid treatment system;
FIG. 7 illustrates a schematic side elevation of orientation of radiation source assemblies in a fourth embodiment of the present fluid treatment system;
FIG. 8 a illustrates a top view (partially cutaway) of a fifth embodiment of the present fluid treatment system;
FIG. 8 b illustrates a top view (partially cutaway) of a sixth embodiment of the present fluid treatment system;
FIG. 9 illustrates a top view of an array of radiation source assemblies incorporating a cleaning device for removing fouling materials from the exterior of the assemblies;
FIG. 10 illustrates vortices generated as fluid flows passes a radiation source assembly of a prior art fluid treatment system;
FIG. 11 illustrates vortices generated as fluid flows passes a radiation source assembly of a fluid treatment system in accordance with the present invention;
FIGS. 12-15 , there is illustrated schematic end views (i.e., viewed through the fluid treatment zone) of a number of embodiments of the staggered/parallel orientation referred to above; and
FIG. 16 illustrates a schematic side elevation of orientation of radiation source assemblies in a highly preferred embodiment of the present fluid treatment system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1 , there is illustrated a fluid treatment system 10 . Fluid treatment system 10 comprises an inlet 12 and an outlet 24 . Disposed between inlet 12 and outlet 24 is a fluid treatment zone 20 .
Fluid treatment zone 20 is interconnected to inlet 12 by an inlet transition zone 14 comprising a first transition region 16 and intermediate transition region 18 . Outlet 24 is interconnected to fluid treatment zone 20 by an outlet transition zone 22 .
As illustrated, fluid passes through fluid treatment system 10 (including fluid treatment zone 20 ) in the direction of arrow A.
As shown, each of inlet 12 , inlet transition zone 14 , fluid treatment zone 20 , outlet transition zone 22 and outlet 24 have a closed cross-section. The use of the term “closed cross-section” is intended to mean an enclosure which bounds a flow of fluid on all sides and/or surfaces.
As shown, inlet 12 and outlet 24 have a circular cross-section much like a conventional pipe arrangement. As further illustrated, fluid treatment zone 20 has a square or rectangular cross-section. Of course it is possible to configure fluid treatment zone 20 to have other cross-sectional shapes.
Disposed in fluid treatment zone 20 is a first bank 26 of radiation source assemblies and a second bank 28 of radiation source assemblies. Each radiation source assembly in banks 26 and 28 is elongate and has a longitudinal axis which is angled with respect to the direction of fluid flow (see arrow A or dashed lined 30 which is a projection of arrow A) through fluid treatment zone 20 .
The radiation source assemblies in bank 26 are mounted on one side of fluid treatment zone 20 and have a distal end thereof supported by a support element 32 . Similarly, each radiation source assembly in bank 28 has one end mounted on a side of fluid treatment zone 20 and a distal end thereof supported by support element 32 .
In the result, the array of radiation source assemblies presented by banks 26 and 28 to the flow of fluid is in the form of an V-shaped configuration with the apex of the “V” being pointed toward the flow of fluid. Of course, the apex of the “V” could be pointed in the opposite direction.
Further, while the distal end of each radiation source assembly in banks 26 and 28 is supported by a single support element 32 , other support elements will be apparent of those of skill in the art.
As shown, intermediate transition region 18 serves the purpose of providing a nesting region for the apex of the array of lamps. As such, it is preferred to have the sides of intermediate transition region 18 tapered to a smaller dimension while, in the illustrated embodiment, maintaining the top and bottom at a consistent dimension (this will be discussed further below).
First transition region 16 interconnects intermediate transition region 18 and inlet 12 , and serves the purpose of: (i) reducing the dimension of the enclosure, and (ii) transitioning the cross-section shape from a polygon to a circle. Similarly, outlet transition zone 22 serves to reduce the dimension of the enclosure and transition the cross-sectional shape of the enclosure from a circle to a polygon.
The use of inlet transition zone 14 and outlet transition zone 22 also serves to obviate or mitigate hydraulic head loss problems that might occur if dramatic changes in dimensions of the enclosure were cast into the system.
A second embodiment of the present fluid treatment system will now be discussed with reference to FIGS. 2-5 . In FIGS. 2-5 , elements having the same last two digits as elements appearing in FIG. 1 are attended to denote like elements.
With reference to FIGS. 2-5 , there is illustrated a fluid treatment system 100 . Fluid treatment system 100 comprises an inlet 112 and an outlet 124 . Fluid treatment system 100 further comprises a fluid treatment zone 120 .
Inlet 112 is interconnected to fluid treatment zone 120 by an inlet transition zone 114 . Fluid outlet 124 is interconnected to fluid treatment zone 120 by an outlet transition zone 122 . Inlet transition zone 114 comprises a first transition region 116 and an intermediate transition region 118 .
Disposed in fluid treatment zone 120 is a first bank 126 of radiation source assemblies and a second bank 128 of radiation source assemblies. The orientation of the radiation source assemblies in banks 126 and 128 with respect to the direction of fluid flow through fluid treatment zone 120 is similar as that described above with respect to FIG. 1 .
As shown, the distal portion of each radiation source assembly in banks 126 and 128 is supported by a support post which is disposed transverse to: (i) the direction of fluid flow through fluid treatment zone 120 , and (ii) the longitudinal axis of each radiation source assembly.
As shown, particularly with respect to FIG. 4 , a support post 134 is used for each column of radiation source assemblies in banks 126 and 128 . As further illustrated FIG. 4 , the upstream end of the array of radiation sources comprises a column of radiation source assemblies from bank 126 connected to a support post 134 —i.e., there is no similar column of radiation source assemblies from bank 128 supported by the upstream centre support. This arrangement is reversed at a downstream support post 134 a . Otherwise, each centre post serves the purpose of supporting a distal portion of radiation source assemblies from one column of each of banks 126 and 128 . In some cases support post 134 also acts as a baffle, and likely will act as a protective shield behind which will be parked a cleaning device (described below).
With particular reference to FIGS. 2 and 5 , it can be seen that mounting sleeves 136 are cast or otherwise secured to the exterior surface of fluid treatment zone 120 . The proximal region of each radiation source assembly is received in mounting sleeves 136 and a fluid type seal (not shown) can be achieved in a conventional manner.
As further illustrated in FIGS. 2-5 , inlet 112 and outlet 124 can be adapted to have a suitable standard flange element 113 and 125 , respectively. This facilitates insulation of fluid treatment system 100 in conventional piping. For example, it is possible for flange elements 113 and 125 to be configured for conventional piping sizes between, for example, 12 inches and 72 inches.
With particular reference to FIG. 3 , it will be seen that banks 126 and 128 are arranged as an array of radiation source assemblies that present an obstruction which completely fills fluid treatment zone 120 when the fluid treatment zone 120 is viewed through inlet 112 . In other words, there is no apparent path by which fluid can pass through fluid treatment zone 120 without being forced to detour around a radiation source assembly in banks 126 and/or 128 . This being the case, the axis of each radiation source assembly can be seen by an observer looking along the direction of fluid flow through fluid treatment zone 120 .
This effect is created by partially staggering the orientation of radiation source assemblies in banks 126 and 128 . For example, with reference to FIG. 5 , it can be seen that, proceeding lengthwise along fluid treatment zone 120 , there is partial overlap of an upstream radiation source assembly with a downstream radiation source assembly in a successive manner—see, for example, lines 150 in FIG. 5 which illustrate such a gradual staggering of radiation source assemblies in each of banks 126 and 128 . In other words, a downstream radiation source assembly is partially exposed and partially obscured by an adjacent upstream radiation source assembly. Thus, it can be seen that the complete obstruction of the cross-sectional area the section of fluid treatment zone 120 (i.e., the section in which banks 126 and 128 are disposed) discussed above is not achieved by staggering of two successive columns of radiation source assemblies in banks 126 and 128 such that a downstream radiation source assembly fills the space between a pair of upstream radiation source assemblies. Rather, in this embodiment, three or more columns of such radiation source assemblies are oriented, in combination, to achieve the complete obstruction.
Preferably, each radiation source assembly preferably comprises of an elongate radiation source (e.g. an ultraviolet radiation lamp such as a low pressure high output ultraviolet radiation lamp) disposed within a protective sleeve (e.g. made from a radiation transparent material such as quartz and the like). In some case it may be possible (and preferred) to utilize a radiation source without a protective sleeve (e.g., photon emitting lamps without a protective sleeve).
As can be seen, particularly with reference to FIG. 5 , intermediate region 118 of inlet transition zone 114 has a transverse direction the same as fluid treatment zone 120 . The sides of intermediate region 118 of inlet transition zone 114 are tapered as shown in FIG. 4 . This arrangement allows for the tapering transition on the one hand while leaving adequate room for the apex of the array of radiation sources on the other hand.
The radiation source assemblies in banks 126 and 128 have longitudinal axes which are angled with respect to the direction of fluid flow (arrow A) through fluid treatment zone 120 . The result is an apex-shape orientation of radiation source assemblies in banks 126 and 128 as clearly seen in, for example, FIG. 4 . The angle .alpha. between the respective longitudinal axes of radiation source assemblies in banks 126 and 128 is preferably in the range of from about 15.degree. to about 170.degree., more preferably from about 35.degree. to about 120.degree., even more preferably from about 50.degree. to about 120.degree., most preferably from about 60.degree. to about 90.degree. It will be appreciated by those of skill in the art that, with a fixed length radiation source, the angle will determine the cross sectional area of the reactor. Further, although not illustrated specifically in the drawings herein, it is preferred and desirable to incorporate in the present fluid treatment system a cleaning device for removing fouling materials from the exterior of the radiation source assemblies in banks 126 and 128 .
An example of incorporating a cleaning device in the present fluid treatment system is illustrated schematically in FIG. 9 . As shown, it is possible to incorporate the cleaning device as a sleeve which travels in a reciprocal manner over the exterior of the radiation source assemblies. As shown, a cleaning device 28 is provided for each radiation source assembly in the form of a movable sleeve. In the illustrated embodiment, cleaning device 28 is “parked” such that it is downstream of support post 134 . The nature of cleaning device 28 is not particularly restricted. See, for example, U.S. Pat. No. 6,342,188 [Pearcey et al.] and U.S. Pat. No. 6,646,269 [Traubenberg et al.], both assigned to the assignee of the present invention.
With reference to FIG. 6 , there is illustrated the side elevation, in schematic, of an arrangement of radiation source assemblies. Generally, this arrangement is the same as the V-shaped configuration discussed above. As shown, there is a row B of 6 radiation source assemblies disposed vertically in the fluid treatment zone. Between each pair of radiation source assemblies in row B, there is a pre-determined spacing C.
As illustrated, radiation source assemblies downstream of row B are arranged in a manner whereby more than two subsequent downstream vertical rows of radiation source assemblies are required to partially obscure pre-determined spacing C. In other words, if one were to view the array of radiation source assemblies along arrow D the flow of fluid through pre-determined spacing C would be obstructed as a result of the arrangement of at least two rows of radiation source assemblies downstream of row B. It will be appreciated by those of skill in the art that, with a relatively large enough number of rows B, the staggered radiation source assemblies per row can completely obstruct the line of vision through the staggered array whereas with fewer radiation source assemblies, the line of sight would not be completely obstructed.
As shown, the array of radiation source assemblies includes a quartet of boundary lamps disposed in the same plain at the outer edges of the staggered array, in this embodiment, of the fluid treatment zone. As further illustrated, the array of radiation source assemblies is arranged to define repeating pattern consisting of a parallelogram containing four radiation source assemblies.
FIG. 7 illustrates a schematic similar to the one shown in FIG. 6 with the exception that the staggering of the radiation source assemblies is different from that shown in FIG. 6 . Specifically, it will be seen that the parallelogram repeating pattern referred to above with reference to FIG. 6 does not appear in the arrangement shown in FIG. 7 . Otherwise, FIG. 7 does illustrate the use of boundary lamps and the staggering of subsequent rows of radiation source assemblies such that the gap between pairs of radiation source assemblies in the first row is effectively filled by more than two subsequent rows as one views the array of radiation source assemblies from one end of the fluid treatment zone.
FIG. 8 a is a schematic similar to that shown in FIG. 4 with the exception that two arrays 120 a and 120 b are used in the fluid treatment zone. As shown, each of array 120 a and array 120 b is a V-configuration similar to that shown in FIGS. 1-4 described above.
FIG. 8 b is a schematic similar to that shown in FIG. 4 with the exception that four arrays 120 a , 120 b , 120 c and 120 d are used in the fluid treatment zone. As shown, each of array 120 a , 120 b , 120 c and 120 d is a V-configuration similar to that shown in FIGS. 1-4 described above. Preferably, each array 120 a , 120 b , 120 c and 120 d is arranged as described below with reference to FIG. 16 . In FIG. 8 b , it is preferred that the spacing between adjacent arrays 120 a , 120 b , 120 c and 120 d is equal to the spacing between adjacent pairs lamps in a column of lamps in an array (e.g., dimension X in FIG. 16 ).
With reference to FIG. 10 , there is shown, in schematic, a radiation source assembly E which is disposed such that its longitudinal axes is orthogonal to the direction of fluid flow shown by arrow A—such an orientation is known from the prior art. As will be understood by those of skill in the art, this orientation of radiation source assembly E presents a circular cross-section to the direction of fluid flow shown by arrow A. Consequently, vortices are generated downstream of radiation source assembly E which are random and wide-angled. The result of this is forced oscillation of radiation source assembly E and/or other radiation source assemblies in the vicinity of radiation source assembly E which can lead to breakage thereof.
With reference to FIG. 11 , there is shown, in schematic, a radiation source assembly F orientated in the manner described above with reference to FIGS. 1-4 . In this orientation, radiation source assembly F presents an oval or ellipse cross-section to the direction of the flow of fluid depicted by arrow A. Consequently, vortices downstream of radiation source assembly F are more regular and less likely to create the forced oscillation disadvantages that can result in breakage of the radiation source assembly.
With reference to FIGS. 12-15 , there is illustrated schematic end views (i.e., view thorough the fluid treatment zone) of a number of embodiments of the staggered/parallel orientation referred to above. In FIGS. 12-15 , reference is made to “First”, “Second” and “Third” ( FIG. 13-15 ) when describing a “Bank” of radiation source assemblies. These terms are intended to denote serial placement of a given “Bank” in a direction from an upstream portion to a downstream portion of the fluid treatment zone.
Thus, with reference to FIG. 12 , it will be seen that the rows of radiation source assemblies in the “First Bank” are staggered in two respects: (i) there is a stagger with respect to a downstream (or upstream) “Second Bank” of radiation source assembles, and (ii) there is a stagger between adjacent rows of radiation source assemblies in the “First Bank”. The arrangement of radiation source assemblies shown in FIG. 12 is particularly well suited for application in fluid treatment systems such as those described in the Maarshalkerweerd #2 patents.
With reference to FIG. 13 , there is illustrated another schematic arrangement of radiation source assemblies in accordance with the staggered/parallel orientation referred to above. The arrangement of radiation source assemblies shown in FIG. 13 is particularly well suited for application in open channel fluid treatment systems such as those described in the Maarshalkerweerd #1 Patents. As shown, the arrangement of radiation source assemblies comprises a First Bank, a Second Bank and a Third Bank. It will be seen that, in an end view, for an adjacent trio of rows of radiation source assemblies in the First Bank, the Second Bank and the Third Bank, each of the First Bank and the Third Bank is: (i) staggered with respect to the Second Bank, and (ii) non-staggered respect to the other. The resulting orientation of radiation may be characterized by: (i) an equilateral triangle though the axis of radiation source assemblies in adjacent rows of the same Bank, and (ii) an equilateral triangle though the axis of radiation source assemblies in an adjacent trio rows of the First Bank, the Second Bank and the Third Bank.
With reference to FIGS. 14 and 15 , there are illustrated schematic views of arrangements of radiation source assemblies similar to that discussed above with reference to FIG. 13 . In FIG. 13 , from the left hand reactor wall, the positioning of rows is: First Bank followed by Second Bank followed by Third Bank. In FIG. 14 , from the left hand reactor wall, the positioning of rows is: Second Bank followed by Third Bank followed by First Bank. In FIG. 15 , from the left hand reactor wall, the positioning of rows is: Second Bank followed by First Bank followed by Third Bank.
With reference to FIG. 16 , there is illustrated a highly preferred arrangement of radiation source assemblies for use in the present fluid treatment system. Thus, in FIG. 16 , there is illustrated a schematic arrangement (e.g., specific details support, electrical connection and sealing of the radiation source assemblies has been omitted for clarity) of the radiation source assemblies shown in a side elevation of the fluid treatment system. Each oval in FIG. 16 denotes an opening in a wall of the fluid treatment system through which an end of the radiation soured assembly would emanate. It is preferred to arrange the radiation source assemblies in a manner such as illustrated above with reference to any of FIGS. 1-4 , 8 a and 8 b.
With continued reference to FIG. 16 , there is illustrated a fluid treatment system 200 comprising, in a preferred embodiment, an enclosed (or closed) fluid treatment zone having a reactor ceiling 205 and a reactor floor 240 . Disposed between reactor ceiling 205 and reactor floor 240 are four modules A, B, C and D of radiation source assemblies. Modules A, B. C and D are substantial the same. Those with skill in the art will appreciate that, while four modules are illustrated in FIG. 16 , it is possible to use fewer or greater then four depending on the volume of fluid being treated, the quality of fluid being treated and other factors within the purview of a person skilled in the art.
Each of modules A, B, C and D comprises four rows 210 , 215 , 220 and 225 . As shown, rows 215 and 220 each comprise a series of radiation source assemblies where each adjacent pair of radiation source assemblies in each row are spaced apart in a substantially uniform manner. Specifically, the distance between all adjacent pairs of radiation source assemblies in row 215 is X as is the distance between all adjacent pairs of radiation source assemblies in row 220 .
With reference to rows 210 and 225 , it will be seen that most of the pairs of adjacent radiation source assemblies are equally spaced and, in a preferred embodiment, the spacing is X as shown with respect of rows 215 and 220 . However, rows 210 and 225 also contain a pair of radiation source assemblies with a spacing Y that is less then spacing X used elsewhere in rows 210 and 225 .
As will be seen with reference to module A, a quartet of radiation source assemblies including a single radiation source assembly from each of rows 210 , 215 , 220 and 225 is arranged to define a parallelogram repeating unit E. Parallelogram repeating unit E comprises all of the radiation source assemblies in module A except the pair of boundary radiation source assemblies 230 . Those with skill in the art will appreciate that it is possible to use parallelogram repeating pattern E to scale up or scale down module A (or one or more modules B, C and D) depending on factors such as the volume of fluid being treated and the like.
Another feature of module A is the so-called stagger order of the radiation source assemblies appearing in the parallelogram repeating unit E. As shown, progressing from reactor ceiling 205 to reactor floor 240 , for a given parallelogram repeating pattern E, the following is the order of rows from which the radiation source assembly is derived: 210 , 220 , 215 and 225 . In other words, for a given parallelogram repeating unit E, the sequence of rows progressing from an upstream portion of the fluid treatment zone to a downstream portion of the fluid treatment zone (i.e., 210 , 215 , 220 and 225 ) differs from the sequence of rows progressing from reactor ceiling 205 to reactor floor 240 (i.e., 210 , 220 , 215 and 225 ). This results in the parallelogram repeating unit E and provides advantageous in the ability to efficiently treat fluid passing through fluid treatment system 200 .
Specifically, this so-called stagger order allows for scalability and modulation of the power used to operate the fluid treatment system. By this it is meant that, using a stagger order such as parallelogram repeating pattern E, it is possible to lower the power consumption or even turn off of the power to certain rows of radiation source assemblies within a given module (e.g., one, some or all of modules A, B, C and D) to account for factors such as fluid transmittance, type and/or concentration of a particular contaminant and the like. For example, it is possible to operate the radiation source assemblies in rows 210 and 215 at full power while lowering or turning off the power to the radiation source assemblies in rows 220 and 225 . This allows for advantageous fining tuning of the overall power consumption of the fluid treatment system (power consumption is usually the single largest operating expense associated with the fluid treatment system).
Such fine tuning would be difficult to achieve if the sequence of rows progressing from an upstream portion of the fluid treatment zone to a downstream portion of the fluid treatment zone (i.e., 210 , 220 , 215 and 225 ) was the same as the sequence of rows progressing from reactor ceiling 205 to reactor floor 240 (i.e., 210 , 215 , 220 and 225 ). In this situation, to modify power consumption, it would be necessary to turn off entire modules within the fluid treatment zone resulting in relatively uneven fluid treatment.
With further reference to FIG. 16 , it can be seen that the spacing V between rows 210 and 215 is the same as the spacing between rows 220 and 225 . It can be further seen that the spacing Z between rows 215 and 220 is greater that spacing V. In certain cases, it may be desirable for spacing V and spacing Z to be substantially the same.
Still further, there is a spacing T between adjacent modules A, B, C and D. It can be seen that spacing T is greater than spacing V. In certain cases, it may be desirable for spacing V and spacing T to be substantially the same.
Further, in certain cases, it may be desirable for spacing V, spacing Z and spacing T to be substantially the same.
While this invention has been described with reference to illustrative embodiments and examples, the description is not intended to be construed in a limiting sense. Thus, various modifications of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to this description. For example, while the illustrated embodiments described above with reference to the accompanying drawings relate to a fluid treatment system comprising a fluid treatment zone having a closed cross-section, it is possible and, in some cases, preferred to implement the present fluid treatment system with a fluid treatment zone having an open or other non-closed cross-section (e.g., in an open channel system such as is described in the Maarschalkerweerd #1 Patents referred to above). Still further, it is possible and, in some cases, preferred to implement the present fluid treatment system with a fluid treatment zone having an semi-enclosed cross-section (e.g., such as is described in the Maarschalkerweerd #2 patents referred to above). Still further, it is possible and, in some cases, preferred to implement the present fluid treatment system with a fluid treatment zone that employs so-called “hybrid” radiation source modules (e.g., such as described in United States patent application publication No. 2002/113021 [Traubenberg et al.] or in International Publication Number WO 04/000,735 [Traubenberg et al.]). as stated above, it is possible to incorporate a mechanical or chemical/mechanical cleaning system to remove fouling materials from the exterior of the radiation source assemblies as described various published patent applications and issued patents of Trojan Technologies Inc. Still further, a variety of conventional sealing systems made of a variety of materials may be used in the present fluid treatment system. The selection of sealing materials and the placement thereof to obtain a sufficient seal is not particularly restricted. Still further, it is possible to modify the illustrated embodiments to use weirs, dams and gates upstream, downstream or both upstream and downstream to optimize fluid flow upstream and downstream of the fluid treatment zone defined in the fluid treatment system of the present invention. Still further, it is possible to modify the illustrated embodiments to include sloped and/or stepped channel surfaces such as is disclosed in International Publication Number WO 01/66469 [Brunet et al.]. Still further, it is possible, to modify the illustrated embodiments to include mixers or mixing elements on the walls of the channel of the fluid treatment system and/or the radiation source module, for example as taught in one or more of U.S. Pat. No. 5,846,437 [Whitby et al.], U.S. Pat. No. 6,015,229 [Cormack et al.], U.S. Pat. No. 6,126,841 [Whitby et al.], U.S. Pat. No. 6,224,759 [Whitby et al.] and U.S. Pat. No. 6,420,716 [Cormack et al.], and in International Publication Number WO 01/93995 [Brunet et al.]. Such mixers or mixing elements (sometimes also referred to in the art as “baffles”) can be used to supplement or replace the use of so-called boundary lamps or boundary radiation source assemblies discussed above. Still further, it is possible to modify the illustrated embodiments to provide multiple banks of radiation source assemblies in hydraulic series. Still further, it is possible to modify the illustrated embodiments to utilized a radiation source assembly comprising a plurality of radiation sources disposed in a protective sleeve (i.e., sometimes referred to in the art as a “lamp bundle”). Still further, it is possible to modify the illustrated embodiments in FIGS. 1 and 2 such that banks 126 and 128 are disposed serially rather than in a side-by-side relationship (of course the dimensions of other elements of the fluid treatment system would need to be modified accordingly). It is therefore contemplated that the appended claims will cover any such modifications or embodiments.
All publications, patents and patent applications referred to herein are incorporated by reference in their entirety to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated by reference in its entirety. | A fluid treatment system having: an inlet; an outlet; and a fluid treatment zone disposed therebetween. The fluid treatment zone has: (i) an elongate first radiation source assembly having a first longitudinal axis, and (ii) an elongate second radiation source assembly having a second longitudinal axis. The first and second longitudinal axes are non-parallel to each other and to a direction of fluid flow through the treatment zone. The present fluid treatment system can treat large volumes of fluid (e.g., wastewater, drinking water or the like); it requires a relatively small “footprint”; it results in a relatively lower coefficient of drag resulting in an improved hydraulic pressure loss/gradient over the length of the treatment system; and it results in relatively lower (or no) forced oscillation of the radiation sources thereby mitigating breakage of the radiation source and/or protective sleeve (if present). | 59,763 |
TECHNICAL FIELD
The present disclosure generally relates to medical devices, systems and methods for imaging in biomedical and other medical and non-medical applications, and more particularly, to optical probes for Optical Coherence Tomography (OCT) imaging where a short working distance is needed with a large confocal parameter to image deep into tissue.
BACKGROUND
Various forms of imaging systems are used in healthcare to produce images of a patient. Often, an image of an internal cavity of a patient is required. These cavities can include areas of the digestive system or the respiratory system. When imaging tissue features of these systems, fiber optic endoscopy is often utilized.
One type of fiber optic probe used in an endoscope is based on Optical Coherence Tomography (OCT) techniques. OCT provides structural information on tissue with high resolution. OCT can provide this information in real time and in a non-invasive manner. Many different lens types have been used to construct fiber optic probes. These lenses include fiber lenses, ball lenses and Gradient Index (GRIN) lenses. Lens materials can vary from glass to plastic to silicon.
As shown in FIG. 1 , one type of OCT probe 10 is comprised of an optical fiber 11 having a casing 11 a , a fiber core 11 b , a proximal end 12 and a distal end 13 , a GRIN lens 14 connected directly to distal end 13 of the optical fiber 11 , and a prism 15 connected directly to GRIN lens 14 and configured to deflect light into surrounding tissue T. Probe 10 is typically connected to a coherent light source at proximal end 12 of optical fiber 11 . Probe 10 is typically contained within a sheath S. Sheath S containing probe 10 is inserted into a cavity of a patient to image into tissue T surrounding probe 10 . Sheath S protects probe 10 and tissue T from damage. Fiber core 11 b , GRIN lens 14 and prism 15 are typically connected by fusing the components together or using an epoxy to glue the components together.
An optical probe must be specifically manufactured to conform to optical parameters required for a specific use. Esophageal imaging requires probes of specific design to properly image into surrounding tissue. Typical prior art probes do not provide the specific optical operating parameters required in esophageal imaging. This disclosure describes an improvement over these prior art technologies.
SUMMARY
Accordingly, an optical probe is provided which includes a lens extending along an axis between a first end and a second end. A spacer extends along the axis between a first end and a second end. The first end of the spacer is connected directly to the second end of the lens. A prism is connected directly to the second end of the spacer such that the prism is spaced apart from the lens by the spacer.
BRIEF DESCRIPTION OF THE DRAWINGS
The present disclosure will become more readily apparent from the specific description accompanied by the following drawings, in which:
FIG. 1 is a side, cross-sectional view of a conventional optical probe using a gradient index lens;
FIG. 2 is a side, cross-sectional view illustrating various operating parameters of an optical probe;
FIG. 3 is a side, cross-sectional view of an optical probe having a lens and a prism;
FIG. 4 is a side, cross-sectional view of an optical probe having a spacer, a lens and a prism;
FIG. 5 is a side, cross-sectional view of an optical probe having an elongated lens and a prism;
FIG. 6 is a side, cross-sectional view of an optical probe having a large spacer, a small lens and a prism;
FIG. 7 is a side, cross-sectional view of an optical probe in accordance with the principles of the present disclosure; and
FIG. 8 is a side, cross-sectional view of an optical probe in accordance with the principles of the present disclosure.
Like reference numerals indicate similar parts throughout the figures.
DETAILED DESCRIPTION
The present disclosure may be understood more readily by reference to the following detailed description of the disclosure taken in connection with the accompanying drawing figures, which form a part of this disclosure. It is to be understood that this disclosure is not limited to the specific devices, methods, conditions or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed disclosure.
Also, as used in the specification and including the appended claims, the singular forms “a,” “an,” and “the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. It is also understood that all spatial references, such as, for example, horizontal, vertical, top, upper, lower, bottom, left and right, are for illustrative purposes only and can be varied within the scope of the disclosure. For example, the references “superior” and “inferior” are relative and used only in the context to the other, and are not necessarily “upper” and “lower”.
Reference will now be made in detail to the exemplary embodiments of the present disclosure, which are illustrated in the accompanying figures.
Proper imaging into tissue using an OCT probe requires strict compliance to probe specifications in order to precisely set the optical parameters in a manner that is effective for esophageal imaging. These parameters can include the Rayleigh Range Rz, the confocal parameter b, the waist w, the focal point fp, and the working distance wd. In some embodiments, the parameters include the focal length fl. The term “beam waist” or “waist” as used herein refers to a location along a beam where the beam radius is a local minimum and where the wavefront of the beam is planar over a substantial length (i.e., a confocal length). The term “working distance” as used herein means the distance between the optical axis of the fiber and the waist w.
As stated above, an optical probe must be specifically manufactured to conform to the optical parameters required for effective esophageal imaging. Indeed, esophageal imaging requires probes of specific design to properly image into surrounding tissue T. When using an optical probe without a balloon for esophageal imaging, a short working distance with large confocal parameter is required. In esophageal imaging there is generally about a 1 millimeter (mm) distance between an outer surface of sheath S and tissue T. In attempts to manufacture an optical probe that conforms to these parameters, several designs have been utilized.
One design utilizes a ball lens. A ball lens is difficult to manufacture with little control and correction over aberrations caused by sheaths covering the optical probe. Another design uses a GRIN lens. Unfortunately, the particular GRIN lens/fiber with a significantly greater index of refraction gradient is costly to manufacture with extremely tight tolerances due to the fast gradient index change. Another design utilizes an outer balloon structure to increase the working distance. However, the use of a balloon often deforms the surrounding tissue and also flattens the natural surface features.
Detailed experimentation conducted by the inventor of the present disclosure has produced an optical probe that conforms to the specific requirements of esophageal imaging. Certain aspects of the inventor's experimentation will now be discussed.
FIG. 3 illustrates an optical probe 300 having a GRIN lens 310 directly connected to a prism 320 using epoxy 315 . One or more optical fibers (not shown) would be connected to the end of GRIN lens 310 . The optical fiber(s) may be connected to a light source. A sheath 330 is also illustrated in FIG. 3 . Sheath 330 includes an inner surface 332 defining a passageway 334 having lens 310 and prism 320 removably disposed therein. An end 336 of sheath 330 defines a blunt tip.
Table 1A lists the specifications of the components of optical probe 300 . As shown in Table 1A, GRIN lens 310 has a thickness of 3.2810 mm defined by the distance between an end 335 of lens 310 and an opposite end 340 of lens 310 . Table 1B lists the resulting beam characteristics of probe 300 . As shown in Table 1B, the configuration of probe 300 of FIG. 3 results in a long working distance and a very small waist. Although this results in an acceptable Rayleigh Range Rz of 0.408 mm, the long working distance is unacceptable since the area in focus is to far away from the probe. The area in focus is the confocal parameter centered around the waist.
In attempts to correct for aberration and adjust the optical parameters, the use of a spacer placed between the optical fiber(s) and the lens has been attempted. Indeed, the variance of the spacer is an important factor for determining the waist and the working distance of a probe because as a spacer length increases, the waist becomes smaller and the working distance becomes shorter.
FIG. 4 illustrates an optical probe 400 having a GRIN lens 410 directly connected to a prism 420 using epoxy 415 . Positioned prior to GRIN lens 410 is a spacer 430 , and connected thereto also using an epoxy 425 . One or more optical fibers (not shown) would be connected to an end 435 of spacer 430 . A sheath 440 is also illustrated in FIG. 4 . Sheath 440 includes an inner surface 442 defining a passageway 444 having lens 410 , prism 420 and spacer 430 removably disposed therein. An end 446 of sheath 440 defines a blunt tip.
Table 2A lists the specifications of the components of optical probe 400 . As shown in Table 2A, GRIN lens 410 has a thickness of 3.0000 mm defined by the distance between an end 445 of lens 410 and an opposite end 450 of lens 410 and spacer 430 has a thickness of 1.000 mm defined by the distance between end 455 and an opposite end 460 of spacer 430 . As shown in FIG. 4 , end 445 directly engages end 460 and end 455 is positioned opposite end 450 . Table 2B lists the resulting beam characteristics of probe 400 . As shown in Table 2B, the configuration of probe 400 of FIG. 4 results in a very short focal length and thus a very short working distance and a very small waist. The resulting unacceptable Rayleigh Range Rz is approximately 0.06 mm.
Another attempt was made to adjust the optical parameters into proper working ranges. FIG. 5 illustrates an optical probe 500 having a GRIN lens 510 directly connected to a prism 520 using epoxy 515 . One or more optical fibers (not shown) would be connected to an end 535 of GRIN lens 510 . A sheath 530 is also illustrated in FIG. 5 . Sheath 530 includes an inner surface 532 defining a passageway 534 having lens 510 and prism 520 removably disposed therein. An end 536 of sheath 530 defines a blunt tip.
Table 3A lists the specifications of the components of optical probe 500 . As shown in Table 3A, GRIN lens 510 has a thickness of 3.9200 mm defined by the distance between end 535 an opposite end 540 of lens 510 . Table 3B lists the resulting beam characteristics of probe 500 . As shown in Table 3B, the configuration of probe 500 of FIG. 5 results in a very short focal length and thus a very short working distance and a very small waist. The resulting unacceptable Rayleigh Range Rz is approximately 0.1 mm.
A further attempt was made to adjust the optical parameters into proper working ranges. FIG. 6 illustrates an optical probe 600 having a GRIN lens 610 connected directly to a prism 620 using epoxy 615 . Positioned prior to GRIN lens 610 is spacer 630 , and connected thereto also using an epoxy 625 or fusion spliced. One or more optical fibers (not shown) would be connected to an end 650 of spacer 630 . A sheath 635 is also illustrated in FIG. 6 . Sheath 635 includes an inner surface 660 defining a passageway 662 having lens 610 , prism 620 and spacer 630 removably disposed therein. An end 664 of sheath 635 defines a blunt tip.
Table 4A lists the specifications of the components of optical probe 600 . As shown in Table 4A, GRIN lens/fiber 610 has a thickness of 0.1200 mm defined by the distance between an end 640 of lens 610 and an opposite end 645 of lens 610 and spacer 630 has a thickness of 0.6000 mm defined by the distance between end 650 and an opposite end 655 of spacer 630 . As shown in FIG. 6 , end 640 directly engages end 655 and end 650 is positioned opposite end 645 . Table 4B lists the resulting beam characteristics of probe 600 . As shown in Table 4B, the configuration of probe 600 of FIG. 6 results in a long focal length with a short working distance, achieving close to the desired optical performance. However, issues arise from manufacturing with tight tolerances of the GRIN lens and spacer (less than +/−1.2 micron for the GRIN and less than +/−10 micron for the spacer).
An optical probe must be specifically manufactured to conform to the optical parameters discussed above to be effective for esophageal imaging. Indeed, esophageal imaging requires probes of specific design to properly image into surrounding tissue T. When using an optical probe for esophageal imaging, a short working distance with large confocal parameter is required. In all of the prior attempts the manufacturing tolerances are extremely tight and do not allow for the production of an optical probe that is simple to manufacture and conforms to the optical parameters required in esophageal imaging.
The claimed optical probes differ from the experimental designs discussed above in that a spacer is positioned between a GRIN lens and a prism in each of the optical probes. This design allows for a probe with aberration correction of the outer sheath that is inexpensive to manufacture, possesses much lower tolerances to the manufacturing specifications, and has a short working distance with a large confocal parameter. In some embodiments, the spacer is fused to at least one of the GRIN lens and the prism and the spacer is formed of fused silica.
FIG. 7 illustrates an optical probe 700 in accordance with the principles of the present disclosure. Probe 700 includes at least one lens, such as, for example, a GRIN lens 710 extending between an end 712 and an opposite end 714 along an axis A. One or more optical fibers (not shown) may be connected to end 712 . The optical fiber(s) may be connected to a light source, such as, for example, a coherent light source. End 714 is directly connected to an end 722 of a spacer 720 that extends between end 722 and an opposite end 724 In some embodiments, end 714 is connected to end 722 by fusing end 714 to end 722 together or using an epoxy to glue the components together. End 712 is positioned opposite end 724 such that lens 710 and spacer 720 are coaxial. In one embodiment, an outer surface of lens 710 is flush with an outer surface of spacer 720 when spacer 720 is connected to lens 710 . In some embodiments, lens 710 is a ball lens, conventional lens, or molded lens with a given thickness to perform similar to the GRIN lens. In some embodiments, probe 700 includes one lens 710 or a plurality of lenses 710 . In some embodiments, spacer 720 is formed from a material that is different from a material from which lens 710 is formed. In some embodiments, spacer 720 comprises fused silica. In some embodiments, spacer 720 comprises glass. In some embodiments, spacer 720 comprises an air gap, plastic, index controlled liquid, or any other substance highly transmissive and close to the index of refraction of the prism and lens which aids in manufacturing.
In some embodiments, lens 710 is fused to spacer 720 . In some embodiments, lens 710 is connected to spacer 720 using epoxy 715 . In some embodiments, epoxy 715 is selected to match closely to the index of refraction of the adjoining components to reduce Fresnel Reflection and maintain high transmission In some embodiments, epoxy 715 is an epoxy manufactured by optical adhesive manufactured by Norland Products Inc. or an EpoTek optical adhesive. In some embodiments, epoxy 715 closely matches the index of refraction of at least one of lens 710 and spacer 720 . In one embodiment, the index of refraction of GRIN lens 710 is 1.52 and the index of refraction spacer 720 is 1.467. In some embodiments, epoxy 715 is curable by, for example, UV light. In some embodiments, lens 710 is connected to spacer 720 by frictional engagement, threaded engagement, mutual grooves, screws, adhesive, nails, barbs and/or raised element.
Positioned after spacer 720 is a prism 730 . Prism 730 extends between an end 731 and an opposite end 733 along axis A such that prism 730 is coaxial with lens 710 and spacer 720 . End 731 directly connected to end 724 by fusing end 731 to end 724 or using an epoxy to glue end 731 to end 724 . In one embodiment, prism 730 is a mirror. In some embodiments, prism 730 comprises glass, plastic or fluorite. In some embodiments, prism 730 is, an Amici roof prism, or a Bauernfeind prism.
In some embodiments, prism 730 is fused to spacer 720 . In some embodiments, prism 730 is connected to spacer 720 using epoxy 725 . In some embodiments, epoxy 725 is selected to match closely to the index of refraction of the adjoining components to reduce Fresnel Reflection and maintain high transmission. That is, in some embodiments, epoxy 725 closely matches the index of refraction of at least one of spacer 720 and prism 730 . In some embodiments, epoxy 725 is curable by, for example, UV light and/or heat. In some embodiments, spacer 720 is connected to prism 730 by frictional engagement, threaded engagement, mutual grooves, screws, adhesive, nails, barbs and/or raised element.
In one embodiment, lens 710 has a thickness defined by the distance between ends 712 , 714 that is equivalent or approximately equivalent to (i.e. within 0 to 1%) a thickness of spacer 720 , the thickness of spacer 720 being defined by the distance between ends 722 , 724 . In one embodiment, the thickness of lens 710 is greater than the thickness of spacer 720 . In one embodiment, the thickness of spacer 720 is between about 50% to about 99% of the thickness of lens. In one embodiment, the thickness of spacer 720 is between about 75% to about 95% of the thickness of lens. In one embodiment, the thickness of spacer 720 is between about 85% to about 90% of the thickness of lens. In one embodiment, the thickness of lens 710 is less than the thickness of spacer 720 . In some embodiments, lens 710 has a thickness between about 0.5 mm and about 5.0 mm and spacer 720 has a thickness between about 0.5 mm and about 5.0 mm.
A sheath 740 is also illustrated in FIG. 7 . Sheath 740 includes an inner surface 742 defining a passageway 744 having lens 710 , spacer 720 and prism 730 removably disposed therein such that lens 710 , spacer 720 and prism 730 are rotatable within passageway 744 . An end 746 of sheath 740 is closed so as to define a blunt tip. In some embodiments, at least one of lens 710 , spacer 720 and prism 730 are fixed to sheath 740 by, for example, adhesive applied to an outer surface of lens 710 , spacer 720 and/or prism 730 and surface 742 . In some embodiments, sheath 740 comprises a flexible material. In some embodiments, sheath 740 comprises a rigid material. In some embodiments, sheath 740 comprises at least one section comprising a rigid material and at least one section that comprises a flexible material, the section(s) that comprise(s) the rigid material being distinct from the section(s) that comprise(s) the flexible material. In some embodiments, sheath 740 comprises a non-metal material. In some embodiments, sheath 740 is transparent. In some embodiments, sheath 740 is not transparent and includes one or more openings extending through surface 742 and an outer surface of sheath 740 configured for passage of optical energy, such as, for example, a light path.
Table 5A lists the specifications of the components of one embodiment of optical probe 700 . As shown in Table 5A, in one embodiment of optical probe 700 , GRIN lens 710 has a thickness of 3.0000 mm defined by the distance between ends 712 , 714 and spacer 720 has a thickness of 2.6500 mm defined by the distance between ends 722 , 724 . The combined length of GRIN lens 710 and spacer 720 of 5.6500 mm is prohibitive in most applications since a long optical probe would damage surrounding tissue in tight locations, e.g. an artery. However, esophageal imaging allows for a probe having a greater length thus permitting the dimensions associated with a probe in accordance with the principles of the present disclosure.
Table 5B lists the resulting beam characteristics of the embodiment of probe 700 detailed in Table 5A. As shown in Table 5B, the configuration of probe 700 of FIG. 7 results in a large waist and a short working distance with a large confocal parameter. For example, the beam of the embodiment of probe 700 detailed in Table 5A yields a waist 1/e 2 radius of 20.6 μm-20.0 μm, a working distance of 1.6 mm after sheath 740 , and a confocal parameter of 2.0 mm in air (2.8 mm in tissue). The confocal parameter allows for imaging 2-3 mm deep into surrounding tissue when optical probe 700 is positioned within the anatomy of a patient, such as, for example, in the patient's esophagus. The resulting Rayleigh Range Rz is approximately 1.0 mm in air (1.4 mm in tissue).
Adjustments to the lengths of GRIN lens 710 and spacer 720 within the parameters discussed above allow for adjustment with very tight tolerances to the spot size (i.e. waist) and working distance. Increasing the thickness of GRIN lens 710 decreases the spot size and a decreasing the thickness of GRIN lens 710 increases the spot size. Increasing the thickness of spacer 720 decreases the working distance and a decreasing the thickness of spacer 720 increases the working distance. The tolerances are proportional to the thickness of GRIN lens 710 and thus may be adjusted for by keeping GRIN lens 710 within a preferred range of +/−1% effective focal length from nominal. In one embodiment, lens 710 has a thickness of 3.000 mm will have +/−30 μm).
Problems with aberrations and back reflection are typical in conventional probes. This typically occurs when mating and other surfaces are perpendicular to a light path. Conventional optical probes force this correction by maintaining tight tolerances to component design, while maintaining the perpendicular surfaces. This is usual in the designing of conventional optical probes because the assembly of perpendicular surfaces makes for easier manufacturing.
In order to address the aberrations and back reflection issues, optical probe 700 has been designed such that mating surfaces of probe 700 , such as, for example, end surfaces defined by ends 710 , 712 , 722 , 724 , 731 are not perpendicular to a light path L after light path L reflects from or pass through prism 730 . In some embodiments, surfaces of one or more optical fibers 745 , end surfaces of ends 712 , 714 of GRIN lens 710 , end surfaces of ends 722 , 724 of spacer 720 and upper and lower surfaces 732 , 734 of prism 730 are all off perpendicular to light path L. Optical fiber(s) 745 is/are connected to end 712 . In some embodiments, optical fiber(s) 745 are surrounded by a casing 750 . In some embodiments, end surfaces of ends 710 , 712 , 722 , 724 are all angled between about 1 and about 10 degrees relative to light path L. In one embodiment, end surfaces of ends 710 , 712 , 722 , 724 are all angled relative to axis A such that none of ends 710 , 712 , 722 , 724 are perpendicular to axis A. In some embodiments, ends 710 , 712 , 722 , 724 are angled 4 degrees relative to light path L. In some embodiments, prism 730 is a cylindrical right angle prism. Any gaps or defects that may exist between components of probe 700 , such as, for example, between lens 710 and spacer 720 and/or between spacer 720 and prism 730 are corrected for by epoxies, such as, for example, epoxy 715 and/or epoxy 725 , between the mating surfaces.
The present disclosure has been described herein in connection with an optical imaging system including an OCT probe. Other applications are contemplated. For example, it is envisioned that the devices disclosed herein may be used for imaging any portion of a patient's anatomy, such as, for example, a patient's esophagus, lungs, liver and/or portions related to the patient's esophagus, lungs or liver, such as, for example, bile ducts.
TABLE 1A
Lens Data Manager
Surface
Refract
Y
X
Non-Centered
Surface #
Surface Name
Type
Y Radius
X Radius
Thickness
Glass
Mode
Semi-Aperture
Semi-Aperture
Data
Object
Sphere
Infinity
Infinity
0.0000
Refract
1
Sphere
Infinity
Infinity
0.0000
Refract
0.0000
0.0000
Stop
SMF26_EN
Sphere
Infinity
Infinity
0.0100
SILICA_S
Refract
0.1000
0.1000
3
Spacer
Sphere
Infinity
Infinity
0.0000
SILICA_S
Refract
0.5000
0.5000
Decenter &
Return
4
Grin Len
Sphere
Infinity
Infinity
3.2810
SLW10_NS
Refract
0.3000
0.3000
Decenter &
Return
5
Dummy Su
Sphere
Infinity
Infinity
0.0000
Refract
0.5000
0.5000
Decenter &
Return
6
Right An
Sphere
Infinity
Infinity
0.3550
SILICA_S
Refract
0.3550
0.3550
Decenter &
Return
7
Right An
Sphere
Infinity
Infinity
−0.3550
SILICA_S
Reflect
0.5020
0.3550
Decenter &
Bend
8
X Toroid
Infinity
3.8480
−0.3450
Refract
0.3550
0.3550
Decenter &
Bend
9
Inner_Tu
X Toroid
Infinity
0.7000
−0.2000
Vestami
Refract
0.3550
0.5000
Decenter &
Bend
10
X Toroid
Infinity
0.9000
−1.6000
Refract
0.3550
0.5000
11
Sphere
Infinity
Infinity
0.0000
Refract
0.3917
0.3917
Image
Sphere
Infinity
Infinity
0.0000
Refract
0.3805
0.3805
Decenter &
Return
TABLE 1B
Gaussian Beam Propagation
Zemax Optical Probe Converted
WAVELENGTH = 1300.0 nm
Dimensions = Millimeters
POSITION
FIELD POSITION = (0.00, 0.00)
WAVEFRONT
RADIUS OF
BEAM
CURVATURE
WAIST RADIUS
RADIUS ON
BEAM
BEFORE
PHASE
BEFORE
PROPAGATION DISTANCE
SURFACE
ORIENTATION
REFRACTION
ORIENTATION
REFRACTION
SUR
TO NEXT SURFACE
X
Y
(DEGREES)
X
Y
(DEGREES)
X
Y
DISTANCE
OBJ
0.0000
0.0046
0.0046
0.0
INF
INF
0.0
0.0046
0.0046
−0.0000
1
0.0000
0.0046
0.0046
0.0
INF
INF
0.0
0.0046
0.0046
−0.0000
2
0.0100
0.0046
0.0046
0.0
INF
INF
0.0
0.0046
0.0046
−0.0000
3
0.0000
0.0046
0.0047
0.0
−0.5574
−0.5574
0.0
0.0046
0.0046
0.0000
4
3.2803
0.0046
0.0047
0.0
−0.5574
−0.5574
0.0
0.0046
0.0046
0.0000
5
0.0000
0.0874
0.0876
0.0
4.0374
4.0366
0.0
0.0119
0.0119
−3.9627
6
0.3482
0.0874
0.0876
0.0
2.5367
2.5211
0.0
0.0119
0.0119
−2.4898
7
−0.3623
0.0791
0.1219
0.0
3.3295
3.3323
0.0
0.0119
0.0119
−3.2543
8
−0.3508
0.0705
0.0707
0.0
−2.9766
−2.9795
0.0
0.0119
0.0119
2.8920
9
−0.2015
0.0557
0.0592
0.0
−1.3168
−1.7067
0.0
0.0096
0.0119
1.2772
10
−1.6277
0.0554
0.0547
0.0
−40.8499
−2.4153
0.0
0.0534
0.0120
2.8127
11
0.0663
0.0123
0.0129
0.0
3.8118
1.0606
0.0
0.0122
0.0119
−0.0343
IMG
0.0123
0.0120
0.0
−4.0899
2.0701
0.0
0.0122
0.0119
0.0319
TABLE 2A
Y
X
Surface
Surface
Refract
Semi-
Semi-
Non-Centered
Surface #
Name
Type
Y Radius
X Radius
Thickness
Glass
Mode
Aperture
Aperture
Data
Object
Sphere
Infinity
Infinity
0.0000
Refract
1
Sphere
Infinity
Infinity
0.0000
Refract
0.0000
0.0000
Stop
SMF28_En
Sphere
Infinity
Infinity
0.1000
SILICA_S
Refract
0.1000
0.1000
3
Spacer
Sphere
Infinity
Infinity
1.0000
SILICA_S
Refract
0.5000
0.5000
Decenter &
Return
4
Grin Len
Sphere
Infinity
Infinity
3.0000
SLO10_NS
Refract
0.3000
0.3000
Decenter &
Return
5
Dummy Su
Sphere
Infinity
Infinity
0.0000
Refract
0.5000
0.5000
Decenter &
Return
6
Right An
Sphere
Infinity
Infinity
0.3550
SILICA_S
Refract
0.3550
0.3550
Decenter &
Return
7
Right An
Sphere
Infinity
Infinity
−0.3550
SILICA_S
Reflect
0.5020
0.5020
Becenter &
Bend
8
X Toroid
Infinity
3.8480
−0.3450
Refract
0.3550
0.3550
Becenter &
Bend
9
Inner_Tu
X Toroid
Infinity
0.7000
−0.2000
Vestami
Refract
0.5000
0.5000
Becenter &
Bend
10
X Toroid
Infinity
0.9000
−0.0500
Refract
0.5000
0.5000
11
Sphere
Infinity
Infinity
0.0000
Refract
0.1008
0.1008
Image
Sphere
Infinity
Infinity
0.0000
Refract
0.0965
0.0965
Decenter
TABLE 2B
Gaussian Beam Propagation
WAVELENGTH = 1300.0 NM
Dimensions = Millimeters
POSITION
FIELD POSITION = (0.00, 0.00)
WAVEFRONT
RADIUS OF
BEAM
CURVATURE
WAIST RADIUS
RADIUS ON
BEAM
BEFORE
PHASE
BEFORE
PROPAGATION DISTANCE
SURFACE
ORIENTATION
REFRACTION
ORIENTATION
REFRACTION
SUR
TO NEXT SURFACE
X
Y
(DEGREES)
X
Y
(DEGREES)
X
Y
DISTANCE X
OBJ
0.0000
0.0046
0.0046
0.0
INF
INF
0.0
0.0046
0.0046
−0.0000
1
0.0000
0.0046
0.0046
0.0
INF
INF
0.0
0.0046
0.0046
−0.0000
2
0.0100
0.0046
0.0046
0.0
INF
INF
0.0
0.0046
0.0046
−0.0000
3
1.0000
0.0046
0.0047
0.0
−0.5574
−0.5574
0.0
0.0046
0.0046
0.0100
4
2.9993
0.0630
0.0631
0.0
−1.0154
−1.0154
0.0
0.0046
0.0046
1.0100
5
0.0000
0.0787
0.0789
0.0
1.6102
1.6088
0.0
0.0053
0.0053
−1.6029
6
0.3472
0.0787
0.0789
0.0
1.0117
1.0038
0.0
0.0053
0.0053
−1.0071
7
−0.3633
0.0600
0.0923
0.0
1.1188
1.1172
0.0
0.0053
0.0053
−1.1100
8
−0.3506
0.406
0.0406
0.0
−0.7597
−0.7282
0.0
0.0053
0.0053
0.7468
9
−0.2015
0.0124
0.0139
0.0
−0.1635
−0.1894
0.0
0.0050
0.0053
0.1367
10
−0.0509
0.0056
0.0059
0.0
−0.6310
−0.2849
0.0
0.0055
0.0053
0.0203
11
0.0160
0.0061
0.0057
0.0
0.1898
0.2313
0.0
0.0055
0.0053
−0.0344
IMG
0.0057
0.0053
0.0
0.3097
0.7957
0.0
0.0055
0.0053
−0.0183
TABLE 3A
Lens Data Manager
Surface
Refract
Y
X
Non-Centered
Surface #
Surface Name
Type
Y Radius
X Radius
Thickness
Glass
Mode
Semi-Aperture
Semi-Aperture
Data
Object
Sphere
Infinity
Infinity
0.0000
Refract
1
Sphere
Infinity
Infinity
0.0000
Refract
0.0000
0.0000
Stop
SMF28_EN
Sphere
Infinity
Infinity
0.0100
SILICA_S
Refract
0.1000
0.1000
3
Spacer
Sphere
Infinity
Infinity
0.0000
SILICA_S
Refract
0.5000
0.5000
Decenter &
Return
4
Grin Len
Sphere
Infinity
Infinity
3.9200
SLW10_NS
Refract
0.3000
0.3000
Decenter &
Return
5
Dummy Su
Sphere
Infinity
Infinity
0.0000
Refract
0.5000
0.5000
Decenter &
Return
6
Right An
Sphere
Infinity
Infinity
0.3550
SILICA_S
Refract
0.3550
0.3550
Decenter &
Return
7
Right An
Sphere
Infinity
Infinity
−0.3550
SILICA_S
Reflect
0.5020
0.3550
Decenter &
Bend
8
X Toroid
Infinity
3.8480
−0.3450
Refract
0.3550
0.3550
Decenter &
Bend
9
Inner_Tu
X Toroid
Infinity
0.7000
−0.2000
Vestami
Refract
0.5000
0.5000
Decenter &
Bend
10
X Toroid
Infinity
0.9000
−1.1000
Refract
0.5000
0.5000
11
Sphere
Infinity
Infinity
0.0000
Refract
0.1145
0.1145
Image
Sphere
Infinity
Infinity
0.0000
Refract
0.1101
0.1101
Decenter &
Return
TABLE 3B
Gaussian Beam Propagation
WAVELENGTH = 1300.0 NM
Dimensions = Millimeters
POSITION
FIELD POSITION = (0.00, 0.00)
WAVEFRONT
RADIUS OF
BEAM
CURVATURE
WAIST RADIUS
RADIUS ON
BEAM
BEFORE
PHASE
BEFORE
PROPAGATION DISTANCE
SURFACE
ORIENTATION
REFRACTION
ORIENTATION
REFRACTION
SUR
TO NEXT SURFACE
X
Y
(DEGREES)
X
Y
(DEGREES)
X
Y
DISTANCE X
OBJ
0.0000
0.0046
0.0046
0.0
INF
INF
0.0
0.0046
0.0046
−0.0000
1
0.0000
0.0046
0.0046
0.0
INF
INF
0.0
0.0046
0.0046
−0.0000
2
0.0100
0.0046
0.0046
0.0
INF
INF
0.0
0.0046
0.0046
−0.0000
3
0.0000
0.0046
0.0047
0.0
−0.5574
−0.5574
0.0
0.0046
0.0046
0.0100
4
3.9195
0.0046
0.0047
0.0
−0.5574
−0.5574
0.0
0.0046
0.0046
0.0100
5
0.0000
0.0677
0.0678
0.0
1.7153
1.7150
0.0
0.0066
0.0066
−1.6992
6
0.3516
0.0677
0.0678
0.0
1.0777
1.0691
0.0
0.0066
0.0065
−1.0676
7
−0.3591
0.0524
0.0809
0.0
1.2121
1.2111
0.0
0.0066
0.0066
−1.1931
8
−0.3513
0.369
0.0370
0.0
−0.8612
−0.8603
0.0
0.0066
0.0066
0.8341
9
−0.2016
0.0142
0.0157
0.0
−0.2338
−0.2687
0.0
0.0061
0.0065
0.1899
10
−0.1018
0.0084
0.0088
0.0
−0.4062
−0.3198
0.0
0.0071
0.0066
0.1142
11
0.0190
0.0069
0.0067
0.0
0.631
0.8110
0.0
0.0068
0.0065
−0.0214
IMG
0.0068
0.0065
0.0
5.0095
−1.9007
0.0
0.0068
0.0065
−0.0024
TABLE 4A
Lens Data Manager
Surface
Refract
Y
X
Non-Centered
Surface #
Surface Name
Type
Y Radius
X Radius
Thickness
Glass
Mode
Semi-Aperture
Semi-Aperture
Data
Object
Sphere
Infinity
Infinity
0.0000
Refract
1
Sphere
Infinity
Infinity
0.0000
Refract
0.0000
0.0000
Stop
SMF28_EN
Sphere
Infinity
Infinity
0.0100
SILICA_S
Refract
0.1000
0.1000
3
Spacer
Sphere
Infinity
Infinity
0.6000
SILICA_S
Refract
0.1000
0.1000
Decenter &
Return
4
Grin Len
Sphere
Infinity
Infinity
0.1200
SLW10_NS
Refract
0.1000
0.1000
Decenter &
Return
5
Dummy Su
Sphere
Infinity
Infinity
0.0000
Refract
0.1000
0.1000
Decenter &
Return
6
Right An
Sphere
Infinity
Infinity
0.3550
SILICA_S
Refract
0.3550
0.3550
Decenter &
Return
7
Right An
Sphere
Infinity
Infinity
−0.3550
SILICA_S
Reflect
0.5020
0.3550
Decenter &
Bend
8
X Toroid
Infinity
3.8480
−0.3450
Refract
0.3550
0.3550
Decenter &
Bend
9
Inner_Tu
X Toroid
Infinity
0.7000
−0.2000
Vestami
Refract
0.5000
0.5000
Decenter &
Bend
10
X Toroid
Infinity
0.9000
−1.0000
Refract
0.5000
0.5000
11
Sphere
Infinity
Infinity
−1.0000
Refract
0.2820
0.2820
Image
Sphere
Infinity
Infinity
0.0000
Refract
0.4220
0.4220
Decenter &
Return
TABLE 4B
Gaussian Beam Propagation
WAVELENGTH = 1300.0 NM
Dimensions = Millimeters
POSITION
FIELD POSITION = (0.00, 0.00)
WAVEFRONT
RADIUS OF
BEAM
CURVATURE
WAIST RADIUS
PROPAGATION
RADIUS ON
BEFORE
PHASE
BEFORE
DISTANCE TO
SURFACE
BEAM ORIENTATION
REFRACTION
ORIENTATION
REFRACTION
DISTANCE
SUR
NEXT SURFACE
X
Y
(DEGREES)
X
Y
(DEGREES)
X
Y
X
OBJ
0.0000
0.0046
0.0046
0.0
INF
INF
0.0
0.0046
0.0046
−0.0000
1
0.0000
0.0046
0.0046
0.0
INF
INF
0.0
0.0046
0.0046
−0.0000
2
0.0100
0.0046
0.0046
0.0
INF
INF
0.0
0.0046
0.0046
−0.0000
3
0.6000
0.0046
0.0047
0.0
−0.5574
−0.5574
0.0
0.0046
0.0046
0.0100
4
0.1200
0.0382
0.0383
0.0
−0.6190
−0.6190
0.0
0.0046
0.0046
0.6100
5
0.0000
0.0414
0.0415
0.0
4.8938
4.8855
0.0
0.0258
0.0257
−2.9944
6
0.3548
0.0414
0.0415
0.0
3.2911
3.237
0.0
0.0258
0.0258
−2.0137
7
−0.3552
0.0383
0.0585
0.0
4.6633
4.6639
0.0
0.0258
0.0258
−2.5589
8
−0.3501
0.0355
0.0356
0.0
−4.6473
−4.6481
0.0
0.0258
0.0258
2.2037
9
−0.2013
0.0305
0.0323
0.0
−2.2565
−3.3502
0.0
0.0216
0.0257
1.1224
10
−1.0148
0.0317
0.0311
0.0
5.1654
−5.3288
0.0
0.0259
0.0259
−1.7080
11
−0.9412
0.0266
0.0261
0.0
−30.8349
−143.9934
0.0
0.0256
0.0257
0.0939
IMG
0.0296
0.0297
0.0
4.2543
3.6796
0.0
0.0256
0.0257
−08473
TABLE 5A
Lens Data Manager
Surface
Refract
Y
X
Non-Centered
Surface #
Surface Name
Type
Y Radius
X Radius
Thickness
Glass
Mode
Semi-Aperture
Semi-Aperture
Data
Object
Sphere
Infinity
Infinity
0.0000
Refract
1
Sphere
Infinity
Infinity
0.0000
Refract
0.0000
0.0000
Stop
SMF28_EN
Sphere
Infinity
Infinity
0.0100
SILICA_S
Refract
0.1000
0.1000
3
Spacer
Sphere
Infinity
Infinity
0.0000
SILICA_S
Refract
0.5000
0.5000
Decenter &
Return
4
Grin Len
Sphere
Infinity
Infinity
3.0000
SLW10_NS
Refract
0.3000
0.3000
Decenter &
Return
5
Dummy Su
Sphere
Infinity
Infinity
2.6500
SILICA_S
Refract
0.1961
0.1961
Decenter &
Return
6
Right An
Sphere
Infinity
Infinity
0.0000
Refract
0.5000
0.5000
Decenter &
Return
7
Right An
Sphere
Infinity
Infinity
0.3550
SILICA_S
Refract
0.3550
0.3550
Decenter &
Bend
8
Right An
Sphere
Infinity
−0.3550
SILICA_S
Reflect
0.5020
0.3550
Decenter &
Bend
9
X Toroid
Infinity
3.8480
−0.3450
Refract
0.3550
0.3550
Decenter &
Bend
10
Inner_Tu
X Toroid
Infinity
0.7000
−0.2000
Vestami
Refract
0.5000
0.5000
Decenter &
Bend
11
XToroid
Infinity
0.9000
−1.6000
Refract
0.5000
0.5000
12
Sphere
Infinity
Infinity
0.0000
Refract
0.4035
0.4035
Image
Sphere
Infinity
Infinity
0.0000
0.3968
0.3968
Decenter &
Return
TABLE 5B
Gaussian Beam Propagation
WAVELENGTH = 1300.0 NM
Dimensions = Millimeters
POSITION
FIELD POSITION = (0.00, 0.00)
WAVEFRONT
RADIUS OF
BEAM
CURVATURE
WAIST RADIUS
PROPAGATION
RADIUS ON
BEAM
BEFORE
PHASE
BEFORE
DISTANCE TO NEXT
SURFACE
ORIENTATION
REFRACTION
ORIENTATION
REFRACTION
SUR
SURFACE
X
Y
(DEGREES)
X
Y
(DEGREES)
X
Y
DISTANCE X
OBJ
0.0000
0.0046
0.0046
0.0
INF
INF
0.0
0.0046
0.0046
−0.0000
1
0.0000
0.0046
0.0046
0.0
INF
INF
0.0
0.0046
0.0046
−0.0000
2
0.0100
0.0046
0.0046
0.0
INF
INF
0.0
0.0046
0.0046
−0.0000
3
0.0000
0.0046
0.0047
0.0
−0.5574
−0.5574
0.0
0.0046
0.0046
0.0100
4
2.9993
0.0046
0.0047
0.0
−0.5574
−0.5574
0.0
0.0046
0.0046
0.0100
5
2.6517
0.0923
0.0925
0.0
7.2881
7.2860
0.0
0.0200
0.0201
−6.9440
6
0.0000
0.0559
0.0562
0.0
4.2005
4.2188
0.0
0.0200
0.0201
−3.6611
7
0.3718
0.0559
0.0562
0.0
2.9031
2.8961
0.0
0.0200
0.0200
−2.5303
8
−0.3386
0.0510
0.0786
0.0
3.8897
3.9083
0.0
0.0200
0.0201
−3.2893
9
−0.3522
0.0466
0.0468
0.0
−3.6199
−3.6389
0.0
0.0200
0.0201
2.9506
10
−0.2015
0.0383
0.0408
0.0
−1.6448
−2.2429
0.0
0.0161
0.0200
1.3527
11
−1.6273
0.0389
0.0384
0.0
12.3893
−3.2966
0.0
0.0356
0.0202
−2.0236
12
0.0694
0.0206
0.0205
0.0
−85.0579
12.3541
0.0
0.0206
0.0200
0.0123
IMG
0.0206
0.0200
0.0
−12.8684
126.6894
0.0
0.0206
0.0200
0.0816
While the preferred embodiments of the devices have been described in reference to the environment in which they were developed, they are merely illustrative of the principles of the devices. Modification or combinations of the above-described devices, other embodiments, configurations, and methods for carrying out the invention, and variations of aspects of the invention that are obvious to those of skill in the art are intended to be within the scope of the claims. | An optical probe is provided. The optical probe includes a lens extending along an axis between a first end and a second end. A spacer extends along the axis between a first end and a second end. The first end of the spacer is connected to the second end of the lens. A prism is connected to the second end of the spacer such that the prism is spaced apart from the lens by the spacer. | 96,796 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Patent Application Ser. No. 61/602,346, entitled “Deck System and Components”, filed Feb. 23, 2012 and U.S. patent application Ser. No. 13/465,512, entitled, “Deck System and Components”, filed May 7, 2012, the entire disclosures of which are hereby incorporated by reference in its entirety.
BACKGROUND
[0002] 1. Field of the Invention
[0003] Various aspects of the invention relate to structures such as floors, roofing and exterior decking, and more specifically, relate to deck boards, deck planks, porch boards, flooring, the connection of adjacent boards to each other, the connection of the end of boards to each other, and various accessories used with such structures.
[0004] Certain aspects of the invention relate to the management of rain water & melting snow to keep the underside of a deck system substantially dry, providing for storage of articles and the ability to have a first floor patio/deck area underneath it without rain water affecting the enjoyment of the space or reaching the foundation of the house.
[0005] 2. Description of Related Art
[0006] Deck systems are in wide use in both residential and commercial applications. Some deck systems consist of simple wooden boards having a rectangular cross-section each arranged longitudinally parallel to each other onto a supporting structure. Similar systems are in use with the deck boards being made of manmade material such as a composite or plastic based material.
[0007] These known systems sometimes have several disadvantages. For example, the parallel boards usually are spaced apart from each other laterally to some degree, and even if the deck boards are abutting each other along their length, there is generally still some type of gap between them. This gap between the long edges of the boards allows water to pass through. Thus, when natural rain water or a cleaning water, spilled water, melting snow or other liquid contacts the top surface of the deck boards, it will typically leak down through between the deck boards. This can be undesirable in situations where it is preferred that the region under the deck surface be kept dry. Such situations include structures having a deck surface on an upper floor and a residential area on a lower floor beneath the deck surface. Other situations where it is preferred that the region under the deck surface be kept dry include decks having a dirt surface beneath the deck surface. By keeping the dirt surface beneath the deck surface dry, the resident may prevent the dirt beneath the deck surface from becoming a haven for insects and weeds. In other commercial or industrial uses, it is desirable to keep liquids on the upper surface from inadvertently dripping to the lower area. In addition, where deck boards are also end-to-end, there is typically a space between the end surfaces of the deck boards. In some instances a relatively wide space is left between the ends of the deck boards in order to allow for a thermal expansion and contraction of boards placed end to end. This gap also can allow for undesirable fluid leakage or liquid leakage under the deck as described above.
[0008] Another disadvantage of some deck boards is that in some instances it is necessary to screw the deck boards down to the supporting structure and in a conventional rectangular cross-section board, the screw heads are exposed on the top surface which may be undesirable for cosmetic or other reasons.
SUMMARY
[0009] In light of the present need for improved decking systems and accessories, a brief summary of various embodiments is presented. Some simplifications and omissions may be made in the following summary, which is intended to highlight and introduce some aspects of the various embodiments, but not to limit the scope of the invention.
[0010] Various embodiments disclosed herein can relate to new and useful decking board constructions. For example, the decking board may feature an extruded cross-section having a generally tongue-and-groove mating fit between lateral and adjacent boards. In various embodiments, the decking board may be a symmetrical, two sided product, with each side optionally having different pattern or color, thereby creating two products in one. One side of the board may feature an upwardly directed U-shaped hook next to a downwardly directed groove or channel. The other side of the decking board may have a complimentary, but opposite shaped, downwardly directed U-shaped hook adjacent to an upwardly directed groove or channel. When the boards are interlocked side-to-side, each hook will mate into each groove thereby providing secure connection between the boards. Further, since the tongues and grooves are overlapping, there is no vertical path for water on the top of the board to pass in between the boards. In various embodiments, the upwardly directed U-shaped tongue forms a primary water channel to collect and direct water along the length of the structure to the end of the structure.
[0011] In another aspect, a flashing element may be provided to act as a butt joint to connect the butt ends of the boards. The flashing element has a complimentary shape to the upper surface of the board, and can reside in longitudinal grooves that are cut into the butt ends of the boards. The flashing can also be a sharpened and or hardened element which is installed by tapping the first sharp end of the flashing element into the relatively soft edge of the first board, and then bringing the second board into contact with the second end of flashing element and then tapping the far end of the second board so that the second edge of the flashing element is pushed into the relatively soft first end of the second board. When installed, the flashing prevents water from passing downward between the butt ends of the boards. In various embodiments, the flashing allows for expansion and contraction of the boards due to fluctuations between hot and cold environments. In one embodiment, a metal flashing that taps into place can be held in place by an integral structure that then presses or affixes onto one or more edges of the board or boards and holds it in place to make assembly easier.
[0012] Another embodiment of the butt joint involves installation of a polymer part having a primarily “V-shaped” profile that flexes. The polymer part having a primarily “V-shaped” profile is installed between the butt ends of the planks. The flexing of the polymer part ensures a tight fit is maintained during expansion and contraction of the planks.
[0013] In another aspect, the boards may feature one or more longitudinal hollow regions. The longitudinal hollow regions may accept a heating element such as a heatable wire or a heating fluid conduit or hose. Other heating elements such as radiant heating elements or hot air containing passages may reside in or be part of the interior of the board. In some instances, a particular longitudinal hollow shape may be provided, or the heating elements may be embedded in the structure during manufacture.
[0014] In addition, at least one flexible member may be added inside the tongue and groove area on either part to align the planks when originally installed tightly together and to also withstand the expansion and contraction of the planks in the widthwise direction during hot and cold weather. Initially, at points of contact between adjacent tongues and grooves of adjacent boards, a bumper protrusion may be provided on one board which will frictionally engage with a complimentary groove on the other board.
[0015] In another embodiment, a gutter may be added to the perimeter of the deck surface to collect the water that is shed from the surface and direct it downwards in a controlled fashion to connectors connecting to a leader which guides water away from the underside of the deck.
[0016] In another embodiment, the addition of a perimeter element may take the form of a bull nose type extrusion that provides some protection to the end boards when objects come in contact with the end of the deck. This may be particularly useful where the ends of the deck may come in contact with vehicles such as carts or, where the deck is being used as a dock and may come in contact with watercraft.
[0017] In another embodiment, the decking board comprises first and second longitudinal sides. The first longitudinal side has a male projecting member with an upwardly directed rib and the second longitudinal side has a female slot defining a downwardly directed rib. The boards can be interlocked adjacent each other with the upwardly directed rib snapped past the downwardly directed rib to form a frictional engagement therebetween. A central main body portion is disposed in longitudinal sides.
[0018] In another embodiment, the decking board comprises a first longitudinal side having an extension member including a first surface and an opposing second surface, the first surface including an upwardly projected abutment defining a first lip. The second surface has a recess formed therein. The second longitudinal side includes a first portion defining a tongue and a second portion including a second lip. The tongue includes a first flexible member extending generally upward from the first portion. The second lip includes a second flexible member extending generally downward from the second portion.
[0019] a main central body disposed intermediate to the first longitudinal side and second side;
[0020] wherein the first portion and second portion of the second longitudinal side define a cavity therebetween to receive an extension member of an associated decking board therein.
[0021] In another aspect, a dock board may be provided in the form of a relatively simple dock board extrusion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] In order to better understand various exemplary embodiments, reference is made to the accompanying drawings, wherein:
[0023] FIG. 1A shows various elements of a decking system, including decking boards and a flashing element.
[0024] FIG. 1B is a cross-section of the embodiment of FIG. 1A .
[0025] FIG. 1C is a detailed view of a part of the cross-section of FIG. 1B .
[0026] FIG. 1D shows a cross-section of one embodiment of a decking board.
[0027] FIG. 1E shows a cross-section of another embodiment of a decking board.
[0028] FIG. 1F shows a cross-section of yet another embodiment of a decking board.
[0029] FIG. 2A shows a number of decking boards according to the embodiment of FIG. 1F in an installed condition.
[0030] FIG. 2B shows additional details of the system of FIG. 2A .
[0031] FIG. 2C shows a number of decking boards according to the embodiment of FIG. 1E in an installed condition.
[0032] FIG. 3A illustrates a drain and gutter system.
[0033] FIG. 3B is an exploded view of the system of FIG. 3A .
[0034] FIG. 3C is a further exploded view of the system of FIG. 3A .
[0035] FIG. 3D depicts components of the drain and gutter system.
[0036] FIG. 3E shows a drain and gutter system corner connector
[0037] FIG. 4 shows a cross-section of a component of the drain and gutter system having a bull nose profile.
[0038] FIG. 5 shows a simplified decking board in the form of a dock plank.
[0039] FIG. 6 shows a bull nose component for mounting to the end a deck or dock system.
[0040] FIGS. 7A and 7B show polymer parts which aid in connecting planks of FIG. 1 in an end-to-end relationship.
[0041] FIG. 8A is a cross-sectional view of another embodiment of a decking board.
[0042] FIG. 8B shows two decking boards according to FIG. 8A joined together.
[0043] FIG. 9A is a cross-sectional view of another embodiment of a decking board.
[0044] FIG. 9B shows two decking boards according to FIG. 9A joined together.
[0045] FIG. 10A is a cross-sectional view of another embodiment of a decking board.
[0046] FIG. 10B shows two decking boards according to FIG. 10A joined together.
[0047] FIG. 11A is a cross-sectional view of another embodiment of a decking board.
[0048] FIG. 11B is a side view of the board of FIG. 11A .
[0049] FIG. 11C is a bottom view of the board of FIG. 11A .
[0050] FIG. 11D is a top view of the board of FIG. 11A .
[0051] FIG. 11E is a cross-sectional view of two boards according to FIG. 11A mounted together.
[0052] FIG. 12A is a cross-sectional view of another embodiment of a dock board.
[0053] FIG. 12B is a side view of the dock board of FIG. 12A .
[0054] FIG. 12C is a bottom view of the dock board of FIG. 12A .
[0055] FIG. 12D is a top view of the dock board of FIG. 12A .
[0056] FIG. 13A is a side view of a decking board system, illustrating two decking boards in locking engagement.
[0057] FIG. 13B is a cross-sectional view of another embodiment of a decking board.
[0058] FIG. 13C is a sectional view of the decking board of FIG. 13B , further illustrating the decking board connection and fastening component.
[0059] FIG. 13D is a side view of a decking board system of FIG. 13A illustrating the attachment of plural decking boards.
DETAILED DESCRIPTION
[0060] Referring now to the drawings, in which like numerals refer to like components or steps, there are disclosed broad aspects of various exemplary embodiments.
[0061] The board is used herein to refer to any type of longitudinal surface or substrate board. Some embodiments are referred to as decking boards, but any embodiments could be used in porches, floors, roofing or other uses as will be understood by one skilled in the art of construction components.
[0062] Various embodiments disclosed herein can relate to new and useful decking board constructions. For example, the decking board may feature an extruded cross-section having a generally tongue-and-groove mating fit between lateral and adjacent boards. One side of the board may feature an upwardly directed U-shaped hook next to a downwardly directed channel. The other end of the decking board may have a complimentary, but opposite shaped, downwardly directed U-shaped hook adjacent to an upwardly directed groove. When the boards are interlocked side-to-side, each hook will mate into each groove thereby providing secure connection between the boards. Further, since the tongues and grooves are overlapping, there is no vertical path for water on the top of the board to pass in between the boards. In addition, the downwardly directed U-shaped tongue forms a water channel to collect and direct water along the length of the structure to the end of the structure.
[0063] FIG. 1A depicts a deck system 10 including a plurality of decking boards 12 . Each board 12 has a downwardly directed tongue 14 which has an upwardly facing groove 16 . Located inward of the downward facing tongue 14 is a downward facing groove 18 . A reversed structure is provided on the other side of the board 12 including an upward facing tongue 20 having a downward facing channel 22 . Located inward of the upward facing tongue 20 is an upward facing groove 24 . FIG. 1A also shows the boards interconnected with each other with the downward facing tongue 14 residing in the upward facing groove 24 of an adjacent board. The farthest edge 26 of the downward facing tongue 14 slides against a resilient tab 28 . Similarly, the outer surface 30 of the board will abut against a tab 32 in an adjacent board. In the assembled system, therefore, a water collecting channel 40 is provided which appears from the upper surface of the deck as a simple downward rectangular channel. In various embodiments, the boards are symmetrical so the customer can turn the decking boards upside down while still allowing interconnection between the boards. In some embodiments, the symmetrical boards have identical patterns and colors on each side. This contributes to ease of assembly, as each board may be used with either side uppermost. In some embodiments, the symmetrical boards have different patterns or colors on each side. The presence of different patterns or colors on each side of the decking boards allows the customer to choose between two different or complementary surface styles while buying only one board item version.
[0064] In another aspect, a flashing element may be provided to connect the butt ends of the boards. The flashing element has a complimentary shape to the upper surface of the board, and can reside in longitudinal grooves that are cut into the butt ends of the boards. When installed, the flashing element prevents water from passing downward between the butt ends of the boards. This is true even if a relatively wide end to end gap is selected to allow for thermal expansion and contraction.
[0065] Into the end of each board is cut a slot 42 which extends a predetermined distance into the board, but not all the way through its length. The slot 42 is sized to receive the insertion of a flashing element 50 . The flashing element, therefore, resides in the slots 42 in the butt ends of boards 12 placed end to end, and prohibits any water flow between the ends of the boards. To the extent the flashing element 50 is visible between butt end gap between the boards, any liquid that contacts the flashing will be directed into a channel portion 52 of the board and will, once a certain volume of liquid is reached, be carried away by channel 40 . The flashing element 50 can be made from folded or extruded metal and may have its edges sharpened for tapping into place into slots 42 in the butt ends of the boards.
[0066] In various embodiments, the flashing can be a sharpened and/or hardened element which is installed by tapping the first sharp end of the flashing element into the relatively soft end of a first board, and then bringing a second board into contact with the second end of flashing element and then tapping the far end of the second board so that the second edge of the flashing element is pushed into the relatively soft first end of the second board. In such embodiments, the presence of slots 42 in the butt ends of boards 12 is optional.
[0067] A feature of the boards 12 shown in FIG. 1A is that they can be slid together along their length. That is, rather than snapping the boards in together to mate from the top, which is possible, another assembly option is to slide the boards together end to end, one next to another. Accordingly, boards can be assembled into an overlapping deck without the use of any hardware to hold the boards to each other.
[0068] A device for facilitating formation of watertight butt joints is shown in FIG. 7A , It is a polymer part 700 that has a primarily “V-shaped” profile 701 that flexes during installation between the butt ends of the planks. The butt ends of the planks contact the outer surface of the “V-shaped” profile 701 . Flexing of the profile 701 ensures a tight fit is maintained during expansion and contraction of the planks. The polymer part 700 may also have a hidden tape or other sealant material to keep the butt joint in place and provide further water sealant ability. The polymer part 700 may have one or more snap provisions to hold it down in place between the ends of the planks. This “V-shaped” profile 701 directs the water that would normally have fallen between the ends of the planks into channel 702 , which fits into rain grooves 40 in the planks and bridges rain grooves in two planks in an end-to-end relationship. Channel 702 guides water into the rain groove 40 in FIG. 1A .
[0069] Another embodiment of the device for facilitating formation of watertight butt joints is shown in FIG. 7B , and is a polymer part 210 that has a primarily “T-shaped” profile 711 installed between the butt ends of the planks, with the vertical member of the “T-shaped” profile 711 fitting between the butt ends of the boards. The polymer part 710 may have a sealant or tape used to keep it in place and may have one or more snap provisions to keep it in place between the ends of the deck planks. The horizontal member of the “T-shaped” profile 711 covers the top surface of the planks and has a “U-shaped” extension forming channel 712 that fits on top of and spanning the space between the ends of the rain grooves 40 of the planks whose ends are being joined. This embodiment may or may not have some sealant, tape or snap fit to help hold it into place.
[0070] In an alternate embodiment, a device for facilitating formation of watertight butt joints is a polymer part 710 that has a primarily “I-shaped” profile installed between the butt ends of the planks, with the vertical member of the “I-shaped” profile fitting between the butt ends of the boards. The “I-shaped” profile has an upper horizontal member which covers the top surface of the planks and has a “U-shaped” extension forming a channel that fits on top of and spans the space between the ends of the rain grooves 40 of the planks whose ends are being joined. The “I-shaped” profile has a lower horizontal member. The butt ends of the boards fit between the upper and lower horizontal members.
[0071] Device 700 and 710 for facilitating formation of watertight butt joints may have a snap fit feature for securing them between boards.
[0072] Returning to FIG. 1A , the boards may also be assembled by installing a first board having an upwardly facing groove 24 , and then connecting a second board having a downwardly facing tongue 14 to the first board. This is done by placing the downwardly facing tongue 14 of the second board over the already installed first board. Then the second board's downwardly facing tongue 14 is aligned over the first board's upwardly facing groove 24 and the second board is dropped down onto and over the top of the edge of the first board so tongue 14 goes into groove 24 . The second board then slides into the groove 24 of the first board, tightly against the first board, so that the edge 26 of the downward facing tongue 14 slides against a resilient tab 28 in groove 24 . The edge 26 of the downward facing tongue 14 makes tight contact with tab 28 . This creates a perfect alignment between the boards as the installer puts screws down onto the surface of grooves 24 , securing the boards in place. This also contributes to the water tightness of channel 40 , which also has upwardly facing and downwardly facing interconnecting elements. The resilient tab 28 allows for thermal based expansion of the boards after assembly. It may be desirable to mount the boards to an underlying structure (this will be described further with reference to FIG. 2A using the board of FIG. 1F ). The board of FIG. 1A provides a conveniently accessible mounting location for such screws through the surface of the groove 24 , which may or may not be pre-drilled with holes 63 for ease of installation.
[0073] In another aspect, the boards may feature one or more longitudinal hollow regions 62 . The longitudinal hollow regions may accept a heating element such as a heatable wire or a heating or cooling fluid conduit or hose. Other thermal elements such as radiant heating elements or hot air containing passages may reside in or be part of the interior of the board. In some instances, a particular longitudinal hollow shape may be provided, or the heating elements may be embedded in the structure during manufacture.
[0074] The board 12 also includes a main body region 60 . This main body region 60 may be solid or may be provided with one or more hollow regions 62 . The hollow region 62 may provide a number of benefits including, for example, reducing the weight of the board compared to a solid board. Further, the hollow region 62 may allow for the insertion of heating devices. The board depicted in FIG. 1A also features stiffening ribs 64 . These ribs 64 can provide stiffening, and can also maintain heater cables separate from each other if they are installed in back and forth rows.
[0075] It is also noted that the openings 62 may have a wide variety of shapes as are shown in the other figures, and other cross-sectional shapes. In addition to or instead of containing heating elements, other items such as wires for power outlets, speakers, dog fences, or other wire based products may be passed through the hollow portions 62 .
[0076] In another aspect, a flexible assembly tab or member such as tab 28 , 32 and 128 may be provided on the boards near the tongue and groove region to provide a firm frictional contact between the adjacent tongues and grooves and to align the boards during assembly. Initially, at points of contact between adjacent tongues and grooves of adjacent boards, a bumper protrusion may be provided on one board which will frictionally engage with a complimentary groove on the other board. It is also noted that tabs 28 , 32 and 128 provide a stop feature during the assembly process, but further allow for lateral expansion and contraction of the boards during temperature extremes. The tabs 28 , 32 nd 128 may be referred to as flexible members. The resilient or flexible members may provide for alignment and frictional engagement. They may thus be in a slightly bent configuration in the assembled state. However the tabs may also be sacrificial in that they are designed to be breakable or frangible, that is, they may break off upon application of sufficent force during installation of adjacent boards.
[0077] FIG. 1D shows a decking board having a different cross-section from FIG. 1A . This board 112 may be thought of as having a tongue 114 which projects into a groove 124 . An upward facing channel 116 is provided that will function similarly to the channel 16 described above. A resilient tab 128 is also provided. Instead of an upwardly directed tongue, this embodiment features a laterally extending tongue 120 . The tongue 120 can provide for a screw location similar to that in the channel 24 and may or may not be pre-drilled with holes for easy assembly. The tongue 120 can also nest in a rectangular notch 118 provided on the other side of an adjacent board. An additional relief area 119 is provided on the lower surface of the tongue 114 which permits clearance for a screw head. The embodiment of FIG. 1D features a single central hollow area 162 . FIG. 1D also schematically depicts heating elements 170 in hollow portion 162 .
[0078] FIG. 1E shows a deck board similar to the board of FIG. 1D , but without the central hollow area 162 . FIG. 1E shows a decking board having a tongue 114 which projects into a groove 124 . A resilient tab 128 is also provided. This embodiment features a laterally extending tongue 120 . The tongue 120 can nest in a rectangular notch 118 provided on the other side of an adjacent board. The embodiment of FIG. 1D optionally includes a pivot bump 117 , and a pocket 126 . Pocket 126 is adapted to receive a mounting screw. However the pocket 126 can also serve as a track for accepting a longitudinal heating wire 130 as shown.
[0079] FIG. 1F shows a deck board having a similar outer profile to that of FIGS. 1D and 1C , but having a central hollow opening 162 that includes stiffening ribs 164 . FIG. 1D also illustrates that the lower surface of the hollow region 162 has a parabolic concave upward shape to reflect heat upwards. A fastener 66 is shown being screwed into hole 63 for mounting.
[0080] FIGS. 2A and 2B show additional details utilizing the board of FIG. 1F . In this embodiment, the board of FIG. 1F has been further provided with a bump/rib 115 and a corresponding bump/rib 125 . Instead of both items 115 and 125 being projecting bumps, one or the other could be a small groove notch, dimple or detent. It will be appreciated that as shown in the lower portion of FIG. 2A , the bumps/ribs 115 and 125 can engage each other to enhance the frictional connection of adjacent boards. Another bump or protrusion 117 may be placed at the edge of the bottom surface next to 118 . This bumper creates a pivot point for the plank so that when fastening the board at area 120 , the wall tongue 114 is pushed upwards to create a tight fit between the seal elements 115 & 125 . Further, FIG. 2A depicts installation screws being placed through the laterally extending tongues 120 .
[0081] In this embodiment, a top surface 111 of each board 112 has a slightly crowned surface to direct water towards the water channels 140 between the boards. FIG. 2A also shows further details of the interaction between the bump/ribs 115 and 125 , and screws 127 .
[0082] FIG. 2C shows an embodiment in which the board has been further provided with a bump/rib 115 and a corresponding bump/rib 125 . In the embodiment of FIG. 2C , the boards are provided with pockets 126 , and are assembled so that pockets 126 of the boards are aligned under tongues 114 of an adjacent board. The water channel 140 defined by tongue 114 of the adjacent board is thus positioned above pocket 126 . Pocket 126 is provided with heating wire 130 . Heating wire 130 provided in one board thus serves to heat channel 140 defined by tongue 114 of the adjacent board. Channel 140 is a groove for carrying rainwater. Heating wire 130 serves to prevent rainwater or melting snow in channel 140 from freezing.
[0083] At the end of a board, the wire 130 may be bent and wrapped around the end of the plank to an adjacent plank. The wire then fits into pocket 126 on the adjacent plank, and travels longitudinally along the adjacent plank. Notches 131 may be provided at the ends of the boards to guide the wire from one plank to another. Heating wire 130 can be a cylindrical wire or a flat or rectangular wire having two opposed major surfaces and two opposed edge surfaces. If a flat wire is used, then the wire should be arranged so that the opposed major surfaces are vertical, i.e., perpendicular to the upper surface of the boards. If the opposed surfaces are horizontal, it is more difficult to bend the wire at the end of the plank.
[0084] Pocket 126 and heating wire 130 may also be installed in the outer edge of tongue 114 or in groove 124 . Each of these locations places the heating wire in proximity to channel 140 , allowing the heating wire to heat water in the channel.
[0085] In another aspect, a drain system may be provided at the longitudinal end of a deck that is made up of adjacent boards. The drain system may include a main T-downspout piece which collects and directs water to a leader, and individual adjacent gutter pieces that connect to the T-downspout. These can be mounted at the ends of the boards on the supporting structure.
[0086] FIGS. 3A , 3 B, 3 C and 3 D depict various components of a gutter system. The gutter system can be used with any deck that can direct and shed surface water, including the decking systems described herein. The gutter system generally includes a main T-downspout 210 and adjacent gutter pieces 212 . The main T-downspout 210 can connect with a leader downspout 214 . The gutter portions 212 may feature an outwardly curved projecting shape 212 a which may provide some bumper protection for the end of the overall decking structure and provide a pleasing appearance by hiding the cut edges of the planks and hiding the heater wire that may be installed and running through and between each plank. Such a rounded outward portion may also be provided on the main T-downspout (although not shown) or this feature may be provided by a separate cover 216 that can be mounted along with T-downspout to cover it as shown. FIG. 3 illustrates these components and further illustrates a corner piece 318 .
[0087] In another embodiment, the gutter may form a bull nose type extrusion that provides some protection to the end boards when objects come in contact with the end of the deck. This may be particularly useful where the ends of the deck may come in contact with vehicles such as carts or, where the deck is being used as a dock and may come in contact with watercraft. FIG. 4 shows a cross-section of a bull nose structure 400 that can provide a relatively simple gutter and/or bumper item that may be mounted on the edge and the end of a deck system. Alternatively, the lower portion of this type gutter extrusion can be made of various lengths so as to be useful for cutting off and using as a trim board in other areas of the deck as needed.
[0088] In another aspect, a dock board may be in the form of a relatively simple dock board extrusion. FIG. 5 shows a deck board in the form of a relatively simple dock plank. This plank 500 features a relatively flat top surface, tilted sides 512 , and upwardly directed recesses 514 . The recesses 514 may assist with saving weight by still providing longitudinal bending strength.
[0089] In another aspect, a bull nose structure may be provided that does not provide water gutter features, but rather provides a projecting cushion structure at the end of the deck similar to the bull nose described above. FIG. 6 depicts a bull nose structure that can be used similar to the bull nose of FIG. 4 . However, this structure has a different cross-sectional shape with structure 600 has a different cross-sectional shape including a mounting tab 612 , and a rounded compressible projection 614 that has a central lap 616 .
[0090] Any or all of the various deck boards, dock boards, downspouts, gutters or bumpers and other components can be manufactured from any suitable material. In many embodiments, the various items can be manufactured by extrusion methods. Any suitable extrudable material may be used. In some embodiments the boards can be manufactured using a compression molding process. In some examples, the items may be manufactured, by extruding or otherwise, from hydrophobic polymers, i.e., PVC or polyolefins, and hydrophobic coconut coir fibers which have been treated to remove coconut coir therefrom. In various embodiments, the composite items may be manufactured without any step chemically modified coconut coir fibers. However, the disclosure herein is not limited to the use of coconut based materials. For example, as an alternative to coir fibers, extruded materials may include ramie or bamboo fibers to reinforce polymeric products. In other embodiments, the materials may simply be extruded or molded from polymeric and/or wood based composite extrudable or moldable materials. Simple plastics may also be used. Further, it may be preferable to manufacture the flashing of a metal such as stainless steel or extruded metals.
[0091] The decking boards may be made by extrusion of a thermoplastic material, i.e., polyester, polyvinyl chloride, or polyolefin, preferably polyethylene or polypropylene. The thermoplastic material may contain a filler, including organic fillers such as wood powders, wood fibers, and coir fibers; inorganic fillers, such as glass fibers, carbon fibers, mineral fibers, silica, alumina, titania, carbon black, nitride compounds, and carbide compounds. The decking boards may be uncoated, or coated with a decorative coating of paint. The decking boards may be coated with a protective coating. The protective coating may be applied by coating a mixture of monomers and/or oligomers on the completed board, and then curing the coating to form a protective coating.
[0092] Coated decking boards may also be made by coextrusion of:
[0093] a core layer comprising a thermoplastic material, i.e., polyethylene or polypropylene, containing optional fillers, including organic fillers such as wood powders, wood fibers, and coir fibers; inorganic fillers, such as glass fibers, carbon fibers, mineral fibers, silica, alumina, titania, carbon black, nitride compounds, and carbide compounds; and
[0094] a coating layer (such as for example PolyEthylene with additives) of a protective thermoplastic polymer. Suitable protective polymers include polyvinyl chloride; acrylic resins, i.e., poly(ethylene-co-methacrylic acid) (Surlyn®); polyester; polycarbonate; and polystyrene.
[0095] In various embodiments, the coating layer contains UV stabilizers which reduce the likelihood of the core layer undergoing degradation from exposure to ultraviolet light. Such UV stabilizers include organic light stabilizers, such as benzophenone light stabilizers, hindered amine light stabilizers, and benzotriazoles; and inorganic light stabilizers. such as barium metaborate and its hydrates.
[0096] In various embodiments, the coating layer contains antifungal agents which increase resistance of the board to mold and other organisms. The antifungal agents may be incorporated in the coating layer alone, or in both the core and coating layers. Useful antifungal agents for coatings include copper (II) 8-quinolinolate; zinc oxide; zinc-dimethyldithiocarbamate; 2-mercaptobenzothiazole; zinc salt; barium metaborate; tributyl tin benzoate; bis tributyl tin salicylate; tributyl tin oxide; parabens: ethyl parahydroxybenzoate; propyl parahydroxybenzoate; methyl parahydroxybenzoate and butyl parahydroxybenzoate; methylenebis(thiocyanate); 1,2-benzisothiazoline-3-one; 2-mercaptobenzo-thiazole; 5-chloro-2-methyl-3(2H)-isothiazolone; 2-methyl-3(2H)-isothiazolone; zinc 2-pyridinethiol-N-oxide; tetra-hydro-3,5-di-methyl-2H-1,3,5-thiadiazine-2-thione; N-trichloromethyl-thio-4-cyclohexene-1,2-dicarboximide; 2-n-octyl-4-isothiazoline-3-one; 2,4,5,6-tetrachloro-isophthalonitrile; 3-iodo-2-propynyl butylcarbamate; diiodomethyl-p-tolylsulfone; N-(trichloromethyl-thio)phthalimide; potassium N-hydroxy-methyl-N-methyl-dithiocarbamate; sodium 2-pyridinethiol-1-oxide; 2-(thiocyanomethylthio)benzothiazole; and 2-4(-thiazolyl)benzimidazole.
[0097] The coating layer may help provide scratch resistance to the decking board surface, either by using a coating with a polymer which is harder than the core layer or through the use of certain additives. Additives which help increase scratch resistance in coatings include lubricants and very hard mineral fillers, including carbide and nitride ceramics.
[0098] The coating layer may also include inorganic pigments, organic pigments, or dyes as colorants. The coating layer may be embossed with a decorative pattern, i,e., wood grain or imitation stone.
[0099] In situations where a coating layer or “capcoat” is applied by coextrusion. the coating layer has a thickness of from about 0.01 to 0.25 inch, preferably from about 0.02 to 0.15 inch, more preferably from about 0.04 to 0.08 inch. The capcoat may cover the entire longitudinal surface of the board; the top and sides of the board, with the bottom surface being uncoated; or the top of the board, with the bottom surface and sides being uncoated.
[0100] As discussed above, at least one flexible member may be added inside the tongue and groove area on the decking planks to align the planks to help withstand expansion and contraction of the planks. Also, a bumper protrusion may be provided on a board which will frictionally engage with a complimentary groove on another board. In various embodiments made by coextrusion of a core material and a capcoat, these flexible members and bumpers may be formed from the same material as the core material, and optionally coated with the capcoat material. In various embodiments made by coextrusion, these flexible members and bumpers may be formed from the capcoat material alone. In certain embodiments, flexible members and bumpers formed from the capcoat material have increased toughness, resistance to breakage, and flexibility, when compared to embodiments in which flexible members and bumpers are made from the core material, i.e., a wood fiber- or coir fiber-filled polyolefin.
[0101] A further design for a flexible member produced from a capcoat polymer layer can be envisioned to be attached to the outside edge of the tongue portion, i.e., on the outside edge 26 of the tongue 14 , or on the outer surface of rain-groove element 40 , as seen in FIG. 1A . The flexible member produced from the capcoat polymer can thereby set the assembly gap between planks during installation. Additionally, a flexible member produced from the capcoat polymer and positioned on edge 26 may contact an inner surface of groove 24 , when boards are fitted together as in FIG. 1A . This provides a flexible water seal between boards as boards expand with heat and then contract again.
[0102] A further design for a flexible member (not shown in FIG. 1C ) produced from a capcoat polymer layer can be envisioned to be attached to the outer edge of the tongue portion 114 or 116 , as seen in FIG. 1C , and adapted to contact the interior of groove 124 , as seen in FIG. 1C . Contact between flexible members produced from a capcoat polymer layer and groove 124 of FIG. 1C produces a flexible water seal.
[0103] Also, a bumper protrusion may be provided on a board which will frictionally engage with a flexible member made of capcoat material on another board. The cap coat material is a tough resilient polymer, and may be used to produce watertight elements.
[0104] FIG. 8A is a cross-sectional view of a board 800 having a top cap coat 801 and a lower cap coat 802 . A male side of the board 814 includes an upwardly projecting bump 816 and a lower pivot bump 817 . A female side 820 of the board includes a projecting bump 822 that can snap over and interlock with the projecting bump 816 , a flexible tap 832 , which can help hold the boards together in alignment, and accommodate for expansion of the boards, and a water drain channel 824 . Further, the female end has an open area to the inside of the flexible tab 832 which can be sized and dimensioned to receive a heating wire or cable. FIG. 8A shows the heating element 870 as having a generally vertical rectangular cross-section.
[0105] FIG. 8B shows two of the boards 800 interlocked adjacent to each other.
[0106] FIG. 9A is a cross-sectional view of a board 900 having a top cap coat 901 and a lower cap coat 902 . This board is narrower than that of FIG. 81 and thus may be more suitable for use as a porch board in some instances. A male side of the board 914 includes an upwardly projecting bump 916 and a lower pivot bump 917 . A female side 920 of the board includes a projecting bump 922 that can snap over and interlock with the projecting bump 916 , a flexible tap 932 , which can help hold the boards together in alignment, and accommodate for expansion of the boards, and a water drain channel 924 . Further, the female end has an open area to the inside of the flexible tab 932 which can be sized and dimensioned to receive a heating wire or cable. FIG. 9A shows the heating element 970 as having a generally vertical rectangular cross-section.
[0107] FIG. 9B shows two of the boards 900 interlocked adjacent to each other.
[0108] FIG. 10A is a cross-sectional view of a board 1000 having a top cap coat 1001 and a lower cap coat 1002 . A male side of the board 1014 includes an upwardly projecting bump 1016 and a lower pivot bump 1017 . A female side 1020 of the board includes a projecting bump 1022 that can snap over and interlock with the projecting bump 1016 , a flexible tap 1032 , which can help hold the boards together in alignment, and accommodate for expansion of the boards, and a water drain channel 1024 . Further, the female end has an open area to the inside of the flexible tab 1032 which can be sized and dimensioned to receive a heating wire or cable. FIG. 10A shows the heating element 1070 as having a generally vertical rectangular cross-section.
[0109] FIG. 10B shows two of the boards 1000 interlocked adjacent to each other. In this embodiment, the aperture on the female end is shaped more vertically, so that the heating element can be oriented more vertically.
[0110] FIG. 11A is a cross-sectional view of a board 1100 having a top cap coat 1101 and a lower cap coat 1102 . A male side of the board 1114 includes an upwardly projecting bump 1116 and a lower pivot bump 1117 . A female side 1120 of the board includes a projecting bump 1122 that can snap over and interlock with the projecting bump 1116 , a flexible tab 1132 , which can help hold the boards together in alignment, and accommodate for expansion of the boards, and a water drain channel 1124 . Further, the female end has an open area to the inside of the flexible tab 1132 which can be sized and dimensioned to receive a heating wire or cable. FIG. 11A shows the heating element 1170 as having a generally vertical rectangular cross-section.
[0111] FIG. 11B shows two of the boards 1100 interlocked adjacent to each other.
[0112] The female sided of the boards of FIGS. 8A through 11D form a partially enclosed conduit for holding the heating element 870 , 970 , 1070 , 1170 , etc. When the boards are installed adjacent each other the male sides in some embodiments will substantially enclose the female-side conduit so the heating element is not exposed to water.
[0113] FIGS. 12A-12D show the cross-sectional and other views of a dock board 1200 .
[0114] Referring now to FIGS. 13A-13D , there is shown a decking board system 1312 including plural decking boards, in interlocking position. As shown in FIGS. 13A and 13B , the decking board 1300 generally includes a top cap coat 1301 and lower cap coat 1302 , as similarly disclosed in previous embodiments. As further shown, the decking board 1300 includes a male side or first longitudinal side 1306 of the decking board, a female side or second longitudinal side 1308 , and a main body 1304 intermediate to the male side 1306 and second side 1308 .
[0115] In the decking system 1312 , the decking boards 1300 are configured for interlocking engagement with each other. As shown, the male side 1306 of the decking board 1300 is configured for cooperative interlocking engagement with the female side 1308 of an associated decking board 1300 . To facilitate this engagement, the male side 1306 generally includes an extension member 1314 , which extends generally laterally outward from the male side 1306 . The extension member 1314 is configured for insertion into the female side 1308 of an associated decking board 1300 in the system 1312 .
[0116] The extension member 1314 generally includes a first surface 1326 and an opposing second surface 1336 defining a notch 1337 . As shown, the extension member 1314 further includes a generally upwardly projecting first lip 1316 positioned, proximate to the first surface 1326 . The extension member 1314 further defines an opening 1338 configured to receive a tongue 1320 from an associated decking board 1300 therein. The configuration of the male side 1306 in combination with the extension member 1314 provides a u-shaped configuration 1340 .
[0117] The female side 1308 of the decking board 1300 generally includes a first portion or tongue 1320 and a second portion 1321 including a second lip 1322 or bump. The first portion 1320 and second portion 1321 have an opening formed therebetween defining a cavity 1362 configured to receive an extension member 1314 of a male side therein.
[0118] As shown in FIG. 13B , the second lip 1322 extends in a generally downward direction from the second portion 1321 and is configured for snapping and/or interlocking engagement with a first lip 1316 provided by an associated decking board 1300 . The second portion 1321 further includes a second flexible member 1324 , positioned generally adjacent to the second lip 1322 , along the inner surface 1330 of the second portion 1321 .
[0119] The second flexible member 1324 extends in a generally downward direction from the inner surface 1330 such that when the decking board 1300 is in locking engagement with an associated decking board, the second flexible member 1324 engages the surface 1326 of the extension member 1314 . The second flexible member 1324 has at least one prong extending generally downward. As shown in FIG. 13C , the second flexible member 1324 may have a two-prong configuration for engagement with the extension member 1314 . The first prong 1333 of the second flexible member 1324 may form a second seal, and the second prong 1331 of the second flexible member 1324 may form a third seal. Notably it is contemplated that the second flexible member 1324 can include more than two prongs 1331 , 1333 , without departing from the scope of the present invention. It is further contemplated that multiple second flexible members 1324 can be provided on the inner surface 1330 to provide additional seals with the extension member 1314 , without departing from the scope of the present invention.
[0120] The tongue 1320 extends generally laterally outward from the female side 1308 . As shown, the tongue 1320 has a generally sloped inner surface 1332 . The female side 1308 of the decking board further includes at least one first flexible member 1328 , which extends from the surface 1332 in a generally upward direction. As such, the first flexible member 1328 is configured for engagement with an extension member 1314 of an associated decking board 1300 Notably it is contemplated that the first flexible member 1328 can include multiple prongs or members to provide multiple points of engagement with the extension member 1314 . Further it is noted that one or more first flexible members 1328 can be provided on the tongue 1320 to provide multiple seals with the extension member 1314 to further block moisture.
[0121] FIGS. 13A and 13D shows a decking board system 1312 including a first decking board 1300 a and a second decking 1300 b, configured to be interlocked adjacent to each other. As shown, the extension member 1314 a of decking board 1300 a is inserted into cavity 1362 b of the decking board 1300 b. The second flexible member 1324 b and first flexible member 1328 b cooperatively engage the extension member 1314 a. As such, the second flexible member 1324 b engages the surface 1326 a of the extension member 1314 a forming a seal, and the first flexible member 1328 b engages the notch or recess 1337 a. The first lip 1316 a of the extension member 1314 a engages the inner surface 1330 b of the decking board 1300 b. The second lip 1322 b of the decking board 1300 b engages the inner surface 1326 a of the decking board 1300 a. Additionally, the tongue 1320 b is inserted below the surface 1338 a.
[0122] As shown in FIG. 13C , the decking board 1300 provides an opening 1342 for receiving a fastening member or component, such as a bolt or screw. As such, the decking board 1300 may be secured to an adjacent surface. Additionally, FIG. 13C illustrates that when the decking boards are in engagement, channel 1340 is formed between the decking boards 1300 a, 1300 b to facilitate fluid removal from the decking board surfaces.
[0123] Although the various embodiments have been described in detail, it should be understand that the invention that the invention is capable of other embodiments and its details are capable of modifications in various obvious respects. As is readily apparent to those skilled in the art, variations and modifications can be affected while remaining within the spirit and scope of the invention. Accordingly, the foregoing disclosure, description, and figures are for illustrative purposes only and do not in any way limit the invention, which is defined only by the claims. | A decking system is made up of a variety of decking boards and other components are disclosed. In some aspects, the decking boards are connectable to each other so that adjacent boards will provide a water barrier and a drainage channel. Some versions of the boards may have a hollow region to accept the provision of heating elements or other accessory structures. A connector piece is disclosed in various embodiments span the gap between the butt ends of the boards to provide a water barrier at the butt ends of the boards. A gutter and downspout system is disclosed, as well as structures for protecting the ends or sides of the deck structure. | 53,828 |
This application claims priority to prior Japanese patent application JP 2004-86757, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a level-conversion circuit and particularly relates to a level-conversion circuit for converting a small-amplitude-signal level and a semiconductor circuit including the level-conversion circuit and/or the small-amplitude-signal-level conversion circuit.
2. Description of the Related Art
In recent years, as the scale of integration and speed of large-scale integrated (LSI) circuits have become increasingly high, the amount of currents consumed by the LSI circuits has raised concerns. For example, where the integration scale of a DRAM increases to two times, the current consumption thereof does not increase to two times. Further, since clock frequencies increase, the increased frequency amount causes the current consumption to increase. Hitherto, measures for decreasing the power-source voltage have been taken, for example, for decreasing the current consumption. To achieve this, the capacities of transistors must be significantly improved, even though in many cases the capacities have already been improved to a level of saturation.
Various types of methods have been proposed, as low-power consumption technologies that require no process-technology development. For example, a reduction of the signal amplitude in long-distance wiring between blocks provided on a chip is significantly effective for reducing operation currents. In the case where a DRAM of about 256 Mbits is used, for example, about 45 percent of an entire burst current IDD4 corresponds to charge/discharge currents flowing in wiring on the chip. Therefore, where the charge/discharge currents in the wiring is decreased to one-second, that is to say, where the signal amplitude in the wiring is decreased to one-second, 22.5 percent of the burst current IDD4 is reduced.
However, several problems arise for decreasing the signal amplitude of the wiring to a small level. First, a level-conversion circuit is required of a circuit for receiving a small-amplitude signal. Hitherto, the level-conversion circuit operates at a low speed and uses the small-amplitude signal at many places, which sacrifices the characteristic of the circuit for receiving the small-amplitude signal. Therefore, the level-conversion circuits have been hardly used.
FIGS. 1A , 1 B, and 1 C show driver circuits for transmitting a small-amplitude signal and FIGS. 2A , 2 B, and 2 C show the waveforms thereof. In general, the output amplitude of a CMOS circuit is determined by the source voltage of a PMOS transistor on the load side and the source voltage of an NMOS transistor on the driver side. In the small-amplitude driver circuits of FIGS. 1A , 1 B, and 1 C, the source voltage of the PMOS transistor is made to be different from that of the NMOS transistor, so as to obtain a small-amplitude signal.
The small-amplitude driver circuit of FIG. 1A includes a power-source voltage VDD, an inverter circuit connected to a ground voltage VSS, a power-source voltage VDDL, and a driving inverter circuit connected to a ground voltage VSSH. The driving inverter circuit transmits the power-source voltage VDDL lower than the power-source voltage VDD to the source voltage of the PMOS transistor on the load side and transmits the ground voltage VSSH higher than the ground voltage VSS to the source voltage of the NMOS transistor on the driver side. Therefore, an input-signal amplitude VDD to VSS is transmitted, as a small amplitude VDDL to VSSH, as shown in FIG. 2A . At that time, a voltage Vgs between the gate and source of the PMOS transistor corresponds to an amplitude VDDL to VSS. Further, a voltage Vgs between the gate and source of the NMOS transistor corresponds to an amplitude VDD to VSSH. Since both voltages are small, an ON current Ids of each of the transistors is small and the capacity for charging and discharging wiring is small. Consequently, the signal-transmission speed of each of the transistors is low. Therefore, the threshold value (Vt) of each of the PMOS and NMOS transistors in an output stage is decreased, so as to be lower than the threshold value of an ordinary transistor. Thus, the ON current of each of the PMOS and NMOS transistors increases, so that the capacity for charging and discharging the wiring and the signal-transmission speed increase.
On the other hand, in each of small-amplitude driver circuits shown in FIGS. 1B and 1C , the voltage of either a transistor on the high-level side or a transistor on the low-level side is low. FIGS. 2B and 2C show the waveforms generated by the small-amplitude driver circuits shown in FIGS. 1B and 1C . In the small-amplitude driver circuit shown in FIG. 1B , the power-source voltage VDDL lower than the power-source voltage VDD is transmitted to the source voltage of the PMOS transistor on the load side and the amplitude level thereof is indicated, as VDDL to VSS. However, where a small-amplitude signal falls, the gate voltage of the NMOS transistor is the power-source voltage VDD and the source voltage thereof is the power-source voltage VSS. Consequently, the voltage Vgs corresponds to the amplitude VDD to VSS. However, where the small-amplitude signal rises, the gate voltage corresponds to the power-source voltage VSS, and the source voltage corresponds to the power-source voltage VDDL. Therefore, the voltage Vgs corresponds to the amplitude VDDL to VSS, the current Ids decreases, and the rising speed of an output signal becomes low. Accordingly, development has been made of a configuration for increasing the signal-transmission speed by decreasing the threshold value of only the PMOS transistor of the driver circuit.
FIGS. 1C and 2C show an example where the ground voltage VSSH higher than the ground voltage VSS is transmitted to the source voltage of the NMOS transistor, where the amplitude level is indicated, as VDDL to VSS. In this example, where a small-amplitude signal rises, the gate voltage of the PMOS transistor corresponds to the ground voltage VSS and the source voltage thereof corresponds to the power-source voltage VDD. Therefore, the voltage Vgs corresponds to the amplitude VDD to VSS. However, where the small-amplitude signal falls, the gate voltage corresponds to the power-source voltage VDD and the source voltage corresponds to the power-source voltage VDDL, so that the voltage Vgs corresponds to the amplitude VDD to VSSH. Consequently, the current Ids decreases and the falling speed of an output signal becomes low. Accordingly, development has been made of a configuration for increasing the signal-transmission speed by decreasing the threshold value of only the NMOS transistor of the driver circuit.
FIG. 3 shows a first known level-conversion circuit. The first known level-conversion circuit receives a small-amplitude signal (VDDL to VSS), as an input signal, and transmits a full-amplitude signal due to a ratio operation of an input stage. Therefore, the capacity of a PMOS transistor of an input-stage circuit is small and that of an NMOS transistor is large, so that the PMOS transistor and the NMOS transistor are made to perform the ratio operation. Accordingly, the falling speed of nodes N 12 and N 13 is high while the rising speed thereof is low. Therefore, even though the first known level-conversion circuit can generate an output signal with high speed at the time where an input signal IN rises, the first known level-conversion circuit generates an output signal with low speed at the time where the input signal IN falls. Specifically, a difference occurs between the signal rising speed and the signal falling speed. Accordingly, the first known level-conversion circuit cannot be used for the case where a signal needs to be caused to transition with high speed at both the falling time and the rising time.
FIG. 4 shows the configuration of a second known level-conversion circuit according to Japanese Unexamined Patent Application Publication No. 2002-135107 disclosing a technology for solving the problems of the above-described first known level-conversion circuit. The second known level-conversion circuit uses a method for preventing an output signal from being affected by the time delay generated due to the ratio operation of a level-conversion unit. In the second known level-conversion circuit configured in the same way as in the case of the first known level-conversion circuit, the rising speed of nodes N 12 and N 13 is high and the falling speed thereof is low due to the ratio operation of the PMOS transistor and the NMOS transistor. The second known level-conversion circuit uses a circuit technology for informing an output signal of only the input-signal rising that causes the second known level-conversion circuit to operate with high speed. However, since one of complementary input stages is slow, a through-current flow between the power-source voltage VDD and the ground voltage VSS is large.
Further, FIG. 5 shows the configuration of a third known level-conversion circuit that is disclosed in Japanese Unexamined Patent Application Publication No. 7-307661 and that is provided for a small-amplitude signal level (VDDL to VSSH). The third known level-conversion circuit operates by the power-source voltage VDDL that is lower than the power-source voltage VDD and the ground voltage VSSH higher than the ground voltage VSS, namely, the signal amplitude VDDL to VSSH. A receiver first stage of the third known level-conversion circuit comprises an inverter buffer circuit and a source-follower transistor for dropping the power-source voltage VDD. When the input signal IN rises and changes, a node N 16 falls and a through-current flow is generated. At that time, the source-follower transistor drops the power-source voltage, so as to reduce the through-current flow. When the input signal falls and changes, the node N 16 rises, so that the output signal OUT falls. Since the output signal OUT falls, a feedback PMOS transistor is turned on, so that the voltage of the node 16 drops to the power-source voltage VDD. Since the operation speed of the third known level-conversion circuit is easily affected by the ratio operation of the PMOS transistor and the NMOS transistor and the configuration in which a full-amplitude circuit receives a small-amplitude signal, the small-amplitude voltage level, the transistor threshold value, and the ratio of the receiver first stage need to be selected with caution so as to prevent the through-current flow being generated.
SUMMARY OF THE INVENTION
The above-described known level-conversion circuits have the following problems. Namely, even though each of the known level-conversion circuits is configured for reducing a through-current flow by increasing the ratio of transistors in the receiver first stage and adding a voltage-drop circuit on the power-source-voltage side, the through-current flow between the power-source voltage and the ground voltage is still large, since a small-amplitude input signal is received by an input stage with a high power-source voltage. Further, for reducing the through-current flow and converting the small-amplitude signal into a power-source-voltage full-swing amplitude signal, the small-amplitude voltage level, the transistor threshold value, the input-stage ratio, and so forth, have to be set under limiting conditions. Therefore, it is difficult to form a level-conversion circuit that satisfies the above-described requirements and operates with high speed.
Accordingly, it is an object of the present invention to provide a level-conversion circuit that solves the above-described problems, has a small through-current flow, consumes a small amount of power, and operates with high speed, and a semiconductor circuit including the level-conversion circuit.
A level-conversion circuit according to an aspect of the present invention comprises an input-timing control unit, a PMOS-driver control unit, an NMOS-driver control unit, and an output unit. The input-timing control unit receives a small-amplitude signal, as an input signal, and transmits an inverted-input signal generated by inverting the input signal. The output unit transmits a large-amplitude output signal according to at least two control signals transmitted from the PMOS-driver control unit and the NMOS-driver control unit to which the input signal and the inverted-and-input signal are transmitted.
Preferably, in the level-conversion circuit, the output unit includes first and second transistors so that where the first transistor is turned on and transmits a first large-amplitude level signal, the second transistor is turned off. Further, where the second transistor is turned on and transmits a second large-amplitude level signal, the first transistor may be turned off.
Preferably, in the level-conversion circuit, the output unit further includes a data-holding unit. Each of the control signals transmitted from the PMOS-driver control unit and the NMOS-driver control unit may be a one-shot-pulse control signal. The output unit may transmit the large-amplitude output signal due to the one-shot-pulse signal, and the data-holding unit may hold the large-amplitude output signal.
Preferably, in the level-conversion circuit, a pulse width of the one-shot-pulse signal may correspond to delay time for generating the inverted-and-input signal.
Preferably, in the level-conversion circuit of the present invention, the large-amplitude output signal may be held by separating the inverted-and-input signal by a non-activation signal and connecting the large-amplitude output signal to the PMOS-driver control unit and the NMOS-driver control unit.
A level-conversion circuit according to another aspect of the present invention comprises an input-timing control unit for receiving third and fourth power-source-level small-amplitude input signals, a PMOS-driver control unit, an NMOS-driver control unit, and an output unit for transmitting first and second power-source-level large-amplitude output signals. The output unit includes a first transistor for transmitting the first power-source-level large-amplitude output signal and a second transistor for transmitting the second power-source-level large-amplitude output signal. Where the first transistor is turned on, the second transistor is turned off, and where the second transistor is turned on, the first transistor is turned off.
Preferably, in the level-conversion circuit, where the small-amplitude input signal is caused to transition from the fourth power-source level to the third power-source level, an output signal transmitted from the PMOS-driver control unit may be caused to transition from the first power-source level to the fourth power-source level and caused to transition to the first power-source level after a predetermined time period. Further, where the small-amplitude input signal is caused to transition from the third power-source level to the fourth power-source level, an output signal transmitted from the NMOS-driver control unit is caused to transition from the second power-source level to the third power-source level and caused to transition to the second power-source level after another predetermined time period.
Preferably, in the level-conversion circuit, the PMOS-driver control unit may comprise a third transistor for transmitting the fourth power-source-level output signal to the output unit and a fifth transistor. The fifth transistor may stop power transmitted from a first power source for a predetermined time period at the instant when the third transistor is turned on and receive the power transmitted from the first power source over a period of time during the third transistor is turned off. The NMOS-driver control unit may comprise a fourth transistor for transmitting the third power-source-level output signal to the output unit, and a sixth transistor. The sixth transistor may stop power transmitted from a second power source for a predetermined time period at the instant when the fourth transistor is turned on and receive the power transmitted from the second power source over a period of time during the fourth transistor is turned off.
Preferably, in the level-conversion circuit, an input signal transmitted to each of gates of the fifth and sixth transistors may be switched to an output signal by using a non-activation signal, so as to hold the output signal.
A level-conversion circuit according to another aspect of the present invention comprises a PMOS-driver control unit, an NMOS-driver control unit, a PMOS-side power-source control unit, an NMOS-side power-source control unit, an output unit, and an output-feedback unit. Each of the PMOS-driver control unit and the NMOS-driver control unit inverts a small-amplitude input signal and transmits the inverted small-amplitude input signal to the output unit. Each of the PMOS-side power-source control unit and the NMOS-side power-source control unit establishes and/or does not establish electrical continuity between the output unit and at least one power source, upon receiving the inverted and output signal and/or a delayed output signal, so that the output unit transmits a large-amplitude output signal.
Preferably, in the level-conversion circuit, each of the PMOS-side power-source control unit and the NMOS-side power-source control unit may transmit a large current to the output unit over a period of time during the output signal is delayed.
A level-conversion circuit according to another aspect of the present invention comprises an output unit including a first transistor for transmitting a first power-source-level large-amplitude output signal and a second transistor for transmitting a second power-source-level large-amplitude output signal, a PMOS-side power-source control unit including third and fourth transistors, and an NMOS-side power-source control unit including fifth and sixth transistors. Where the first transistor is turned on, the third transistor is turned on, the third transistor is turned off after the second power-source-level large-amplitude output signal is caused to transition to the first power-source-level large-amplitude output signal, and the fourth transistor is turned on. Further, where the second transistor is turned on, the fifth transistor is turned off after the first power-source-level large-amplitude output signal is caused to transition to the second power-source-level large-amplitude output signal, and the sixth transistor is turned on.
Preferably, in the level-conversion circuit, each of the third and sixth transistors is turned on after the first power-source-level large-amplitude output signal is caused to transition to the second power-source-level large-amplitude output signal. Further, each of the fourth and fifth transistors may be turned on after the second power-source-level large-amplitude output signal is caused to transition to the first power-source-level large-amplitude output signal.
Preferably, the level-conversion circuit may further comprise a PMOS-driver control unit for receiving a third power-source-level small-amplitude input signal and a fourth power-source-level small-amplitude input signal, and an NMOS-driver control unit for receiving the third power-source-level small-amplitude input signal and the fourth power-source-level small-amplitude input signal. The PMOS-driver control unit may transmit an output signal of the fourth power-source level, upon receiving the third power-source-level small-amplitude input signal, and transmit an output signal of the first power-source level, upon receiving the fourth power-source-level small-amplitude input signal. Further, the NMOS-driver control unit may transmit an output signal of the third power-source level, upon receiving the fourth power-source-level small-amplitude input signal, and transmit an output signal of the second power-source level, upon receiving the third power-source-level small-amplitude input signal.
Preferably, in the level-conversion circuit, the PMOS-driver control unit may comprise a seventh transistor for transmitting the fourth power-source-level output signal, and an eighth transistor for transmitting the first power-source-level output signal. Where the fourth power-source-level output signal is transmitted, the eighth transistor may be turned off. Where the first power-source-level output signal is transmitted, the seventh transistor may be turned off. The NMOS-driver control unit may comprise a ninth transistor for transmitting the third power-source-level output signal, and a tenth transistor for transmitting the second power-source-level output signal. Where the third power-source-level output signal is transmitted, the tenth transistor may be turned off. Further, where the second power-source-level output signal is transmitted, the ninth transistor may be turned off.
Preferably, in the level-conversion circuit, the PMOS-driver control unit may be separated from a first power source and the NMOS-driver control unit may be separated from a second power source by using an activation signal and/or a non-activation signal.
A semiconductor circuit according to another aspect of the present invention comprises at least one of the above-described level-conversion circuits.
A semiconductor circuit according to another aspect of the present invention comprises a driver circuit for generating a third power-source-level signal and a fourth power-source-level signal, a buffer circuit that receives and converts the third power-source-level signal and the fourth power-source-level signal into a first power-source-level signal and a second power-source-level signal and that transmits the converted signals, as the third power-source-level signal and the fourth power-source-level signal, and a level-conversion circuit that receives and converts the third power-source-level signal and the fourth power-source-level signal that are transmitted from the buffer circuit into the first power-source-level signal and the second power-source-level signal.
According to the present invention, an independent control signal is transmitted to each of a driver control unit and an output transistor, so as to prevent the driver control unit and the output transistor from being made to operate at the same time and reduce through-current flows. Further, since the transistor ratio can be selected easily, the degree of designing flexibility increases and the speed enhancement is achieved. Accordingly, a level-conversion circuit that consumes a small amount of power and that operates with high speed can be obtained. Further, a semiconductor circuit including the level-conversion circuit can be obtained.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A shows the configuration of a related driver circuit;
FIG. 1B shows the configuration of another related driver circuit;
FIG. 1C shows the configuration of another related driver circuit;
FIG. 2A shows the waveform of the related driver circuit shown in FIG. 1A ;
FIG. 2B shows the waveform of the related driver circuit shown in FIG. 1B ;
FIG. 2C shows the waveform of the related driver circuit shown in FIG. 1C ;
FIG. 3 shows the configuration of a first known level-conversion circuit;
FIG. 4 shows the configuration of a second known level-conversion circuit;
FIG. 5 shows the configuration of a third known level-conversion circuit;
FIG. 6 shows the configuration of a level-conversion circuit according to a first embodiment of the present invention;
FIG. 7 shows the waveform of the level-conversion circuit of the first embodiment;
FIG. 8 shows the configuration of a level-conversion circuit according to a second embodiment of the present invention;
FIG. 9 shows the configuration of a level-conversion circuit according to a third embodiment of the present invention;
FIG. 10 shows the waveform of the level-conversion circuit of the third embodiment;
FIG. 11 shows the configuration of a level-conversion circuit according to a fourth embodiment of the present invention; and
FIG. 12 shows the configuration of a semiconductor circuit according to a fifth embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Level-conversion circuits of the present invention will now be described with reference to the attached drawings.
First Embodiment
A first embodiment of the present invention will be described in detail with reference to FIGS. 6 and 7 . FIG. 6 shows a level-conversion circuit of this embodiment. A small-amplitude-level voltage inputted thereto includes a high-level voltage VDDL lower than a power-source voltage and a low-level voltage VSSH higher than a ground voltage, where an expression VDDL>VSSH holds. The level-conversion circuit comprises an input terminal 1 , an input-timing control unit 102 , a PMOS-driver control unit 103 , an NMOS-driver control unit 104 , an output-transistor MP 5 , an output-transistor MN 5 , a data-holding unit 105 , and an output terminal 2 .
The input-timing control unit 102 includes a first-stage inverter having a PMOS transistor MP 1 and an NMOS transistor MN 1 , where the transistors MP 1 and MN 1 operate by a power-source voltage VDDL to VSSH and receive an input signal IN. The input-timing control unit 102 further includes a next-stage inverter having a PMOS transistor MP 2 and an NMOS transistor MN 2 , where the transistors MP 2 and MN 2 operate by the power-source voltage VDDL to VSSH and receive the input signal IN. In the first-stage inverter, the source of the PMOS transistor MP 1 is connected to the voltage VDDL, the gate thereof is connected to the input signal IN, and the drain thereof is connected to a node N 1 . Further, the source of the NMOS transistor MN 1 is connected to the voltage VSSH, the gate thereof is connected to the input signal IN, and the drain thereof is connected to the node N 1 . The input signal IN is inverted and the inverted signal is transmitted to the node N 1 . The inverted signal is further transmitted to the next-stage inverter (the transistors MP 2 and MN 2 ) and the gates of transistors MP 3 and MN 3 . In the next-stage inverter, the source of the PMOS transistor MP 2 is connected to the voltage VDDL, the gate thereof is connected to the node N 1 , and the drain thereof is connected to a node N 2 . Further, the source of the NMOS transistor MN 2 is connected to the voltage VSSH, the gate thereof is connected to the node N 1 , and the drain thereof is connected to the node N 2 . The next-stage inverter receives a signal transmitted from the node N 1 functioning as an output end of the first-stage inverter and transmits the output signal to the sources of a PMOS transistor MP 4 and an NMOS transistor MN 4 , as a signal node-N 2 .
The PMOS-driver control unit 103 includes the PMOS transistor MP 3 and the NMOS transistor MN 4 . The source of the PMOS transistor MP 3 is connected to a power-source voltage VDD, the gate thereof is connected to the node N 1 , and the drain thereof is connected to a node N 3 . The source of the NMOS transistor MN 4 is connected to the node N 2 , the gate thereof is connected to the input signal IN, and the drain thereof is connected to the node N 3 . The PMOS-driver control unit 103 transmits its output signal to the gate of an output transistor MP 5 , as a signal node-N 3 . The NMOS-driver control unit 104 includes the NMOS transistor MN 3 and the PMOS transistor MP 4 . The source of the NMOS transistor MN 3 is connected to a ground voltage, the gate thereof is connected to the node N 1 , and the drain thereof is connected to a node N 4 . The source of the PMOS transistor MP 4 is connected to the node 2 , the gate thereof is connected to the input signal IN, and the drain thereof is connected to the node N 4 . The NMOS-driver control unit 104 transmits its output signal to the gate of an output transistor MN 5 , as a signal node-N 4 . Here, the PMOS transistor MP 3 and the NMOS transistor MN 3 are formed, as transistors that have a small capacity, so as to precharge the nodes N 3 and N 4 . Here, expressions MP 3 <<MN 4 and MN 3 <<MP 4 hold. In this event, each of the transistors MP 3 , MN 3 , MP 4 , and MN 4 has a low threshold value (a low voltage Vt).
The source of the output transistor MP 5 is connected to the power-source voltage VDD, the gate thereof is connected to the node N 3 , and the drain thereof is connected to an output OUT. The source of the output transistor MN 5 is connected to a ground voltage VSS, the gate thereof is connected to the node N 4 , and the drain thereof is connected to the output OUT. The data holding unit 105 is provided, as a holding circuit for holding output data. The holding unit 105 includes an inverter circuit INV 1 and an inverter circuit INV 2 . The inverter circuit INV 1 uses the output OUT, as its input end. The inverter circuit INV 2 uses the output end of the inverter circuit INV 1 , as its input end, and transmits its output signal to the output OUT, that is to say, the input end of the inverter circuit INV 1 .
The output transistors MP 5 and MN 5 are separately controlled by the PMOS-driver control unit 103 and the NMOS-driver control unit 104 . The input-signal timing control unit 102 controls the operation timing of the PMOS-driver control unit 103 and the NMOS-driver control unit 104 . The node N 3 generates a one-shot low signal and turns on the output-transistor MP 5 , only when the level of the input signal IN is high, and the node N 4 generates a one-shot high signal and turns on the output-transistor MN 5 , only when the level of the input signal IN is low. Thus, according to the above-described configuration, the output-transistors MP 5 and MN 5 are prevented from being turned on at the same time by selecting a suitable one-shot-signal width. As a result, the output OUT is caused to transition with high speed.
The data holding unit 105 is provided for holding the output data over a period of time during the output transistors MP 5 and MN 5 are turned off. Further, in order to generate the one-shot signal, the signal node-N 2 generated by delaying the input signal IN by the input-timing control unit 102 is transmitted to the sources of the NMOS transistor MN 4 and the PMOS transistor MP 4 . Consequently, the NMOS transistor MN 4 is turned on only over a period of time during the level of the input signal IN is high and the level of the signal node-N 2 is low, so that the node N 3 is caused to transition to the low level. The PMOS transistor MP 4 is turned on only over a period of time during the level of the input signal IN is low and the level of the signal node-N 2 is high, so that the node N 4 is caused to transition to the high level. Over the other periods of time, the inverted signal N 1 generated by delaying the input signal IN is transmitted to the gate of each of the PMOS transistor MP 3 and the NMOS transistor MN 3 . Thus, the node N 3 is precharged to a high level and the node N 4 is precharged to a low level. Therefore, the pulse width of the one-shot signal corresponds to the delay amount of the input-timing control unit 102 .
The source voltage and gate voltage of the PMOS transistor MP 3 are determined to be the voltage VDD and the voltage VDDL, respectively. Therefore, where a predetermined voltage satisfying an expression |Vt|<|VDD−VDDL| is selected, the voltage of the node N 3 is maintained at the VDD level and floating is prevented from occurring. Similarly, where the threshold value Vt of the NMOS transistor MN 3 is determined so that an expression Vt<VSSH−VSS holds, the voltage of the node N 4 is maintained at the VSS level and floating is prevented from occurring. The capacities of the PMOS transistor MP 3 and the NMOS transistor MN 3 are determined to be sufficiently smaller than those of the NMOS transistor MN 4 and the PMOS transistor MP 4 . Consequently, where the NMOS transistor MN 4 and the PMOS transistor MP 4 are turned on, the PMOS transistor MP 3 and the NMOS transistor MN 3 are slightly turned on for maintaining the node potential. The one-shot signals of the nodes N 3 and N 4 fall and rise with high speed. Further, upon receiving the signal transmitted from the node N 1 , the PMOS transistor MP 3 and the NMOS transistor MN 3 enter the ON-state, and the PMOS transistor MP 4 and the NMOS transistor MN 4 enter the OFF-state upon receiving the signal transmitted from the node N 2 , so that the nodes N 3 and N 4 rise and fall with high speed. Thus, the one-shot signals of the nodes N 3 and N 4 can operate with high speed.
Further, low voltages Vt are used for the PMOS transistor MP 4 and the NMOS transistor MN 4 for increasing the circuit-operation speed. Still further, low voltages Vt are used for the PMOS transistor MP 3 and the NMOS transistor MN 3 for obtaining the precharge capacity. However, the use of low voltages Vt may become unnecessary according to the small-amplitude-signal level. Specifically, the entire transistors can be formed, as normal transistors. In this embodiment, the input-timing control unit 102 includes the first-stage inverter and the next-stage inverter with a small capacity. However, the present invention may be achieved without being limited to the above-described configuration, so long as the timing of the input signal IN can be delayed.
Next, the operations of the level conversion circuit shown in FIG. 1 will be described with reference to FIG. 7 illustrating the input timing. Where the input signal IN is caused to transition from the voltage VSSH (>VSS) to the voltage VDDL (<VDD), the PMOS transistor MP 1 and the NMOS transistor MN 1 transmit a predetermined signal created by delaying the timing of the input signal IN and inverting the input signal IN to the node N 1 . Then, the PMOS transistor MP 2 and the NMOS transistor MN 2 transmit the signal node-N 2 created by delaying the input signal IN of the node N 1 . Since the voltage VDDL and the voltage VSSH are used for the signal node-N 1 and the signal node-N 2 , as power sources, output signals transmitted from the nodes N 1 and N 2 perform the VDDL operation and the VSSH operation. Although the input signal IN is directly transmitted to the NMOS transistor MN 4 , the NMOS transistor MN 4 changes from the OFF-state to the ON-state, so as to draw a predetermined number of electrical charges from the node N 3 . Consequently, the level of the node N 3 becomes low (VSSH).
Where the node N 2 changes from the low level to the high level, the NMOS transistor MN 4 is turned off. However, since the node N 1 is switched from the high level (VDDL) to the low level (VSSH) at about the same time, the node N 3 is precharged to the VDD level. Upon receiving the voltage of the node N 3 , the PMOS transistor MP 5 is turned on and the output OUT is caused to transition from the low level to the high level. Since the node N 4 is maintained at the low level then, the NMOS transistor MN 5 remains turned off. Specifically, the NMOS transistor MN 5 remains turned off over a time period during the PMOS transistor MP 5 is turned on. Therefore, no through-current flows are generated in this path.
Where the input signal IN is caused to transition from the voltage VDDL (<VDD) to the voltage VSSH (>VSS), the input signal IN is directly transmitted to the PMOS transistor MP 4 . At this time, the PMOS transistor MP 4 is switched from the OFF state to the ON state so that the node N 4 is charged to a high level (VDDL). When the node N 2 is switched from the high level to the low level, the PMOS transistor MP 4 is turned off. However, since the node N 1 is switched from the low (VSSH) level to the high (VDDL) level at about the same time, a predetermined number of electrical charges is drawn from the node N 4 so that the level of the node N 4 is decreased to the low (VSS) level. Upon receiving the voltage of the node N 4 , the NMOS transistor MN 5 is turned on and the output OUT is caused to transition from the high level to the low level. Since the node N 3 is maintained at the high level then, the PMOS transistor MP 5 remains turned off. Specifically, the PMOS transistor MP 5 remains turned off over a period of time during the NMOS transistor MN 5 is turned on. Therefore, no through-current flows are generated in this path.
Thus, according to the above-described embodiment, an input signal, a delayed and inverted input signal, and a delayed input signal are transmitted to the PMOS and NMOS driver control units 103 and 104 . Further, the ON state and the OFF state of the transistors of the driver circuits are separately controlled. Consequently, the PMOS and NMOS driver control units 103 and 104 generate no through-current flows and operate with high speed. Further, since signals generated by the PMOS and NMOS driver control units 103 and 104 are transmitted to the transistors of the output unit, the transistors can be controlled separately. Thus, the output unit generates no through-current flows and operates with high speed.
Second Embodiment
A second embodiment of the present invention will now be described in detail with reference to FIG. 8 . In this drawing, an example level-conversion circuit of this embodiment is shown. The operations of the level-conversion circuit of this embodiment are almost the same as those of the level-conversion circuit of the first embodiment. However, in the first embodiment, low voltages Vt are used for the transistors MP 3 , MN 3 , MP 4 , and MN 4 for increasing the operation speed. As a result, where the threshold value of each of the transistors using low voltages Vt is depressed or significantly low, a current Ioff (a sub-threshold leak current) is generated, even though the voltage Vgs is 0 V. Where only one level-conversion circuit is provided, the current Ioff is negligible. However, in the case of a VLSI circuit including a plurality of the above-described level-conversion circuits, the total value of the above-described leak currents is often significantly high. In this embodiment, therefore, the level-conversion circuit is provided with measures against the sub-threshold leak currents.
Where the level of a signal ACT functioning as an external control signal is high and the level-conversion circuit operates, the sub-threshold leak current is acceptable. However, where the level of the ACT signal is low and the level-conversion circuit does not operate, namely, where the level-conversion circuit stays in the standby state, the level-conversion circuit is controlled, so as to cut the sub-threshold leak current.
In comparison to the level-conversion circuit of the first embodiment, an activation signal ACT and a signal/ACT generated by inverting the activation signal ACT is transmitted to the level-conversion circuit of this embodiment, as an additional control signal. Further, the following circuits are added to the level-conversion circuit of this embodiment. More specifically, a transfer switch TG 1 including a PMOS transistor MP 8 and an NMOS transistor MN 8 is inserted between the node N 1 and the output OUT. Further, a transfer switch TG 2 including a PMOS transistor MP 7 and an NMOS transistor MN 7 is inserted between the node N 1 and the transistors MP 1 and the MN 1 . Still further, PMOS transistors MP 6 and MP 9 are inserted in parallel between the PMOS transistor MP 3 and the power-source voltage VDD. The gate of the PMOS transistor MP 6 is connected to the node N 1 and the gate of the PMOS transistor MP 9 is connected to the inverted-activation signal/ACT.
Moreover, the NMOS transistors MN 6 and NM 9 are inserted in parallel between the NMOS transistor MN 3 and the ground voltage VSS. The gate of the NMOS transistor MN 6 is connected to the node N 1 and the gate of the NMOS transistor MN 9 is connected to the activation signal ACT. Where the level of the signal ACT is high, the transfer switch TG 2 is turned on and outputs transmitted from the PMOS transistor MP 1 and the NMOS transistor MN 1 are connected to the node N 1 . Conversely, where the level of the signal ACT is low, the transfer switch TG 2 is turned off, and the node N 1 is connected to the output OUT via the transfer switch TG 1 . Where the level of the signal ACT is high, the transfer switch TG 1 remains turned off. However, where the level of the signal ACT is low, the transfer switch TG 1 is selected, so as to connect the output OUT to the node N 1 . Where the level of an externally transmitted signal ACT is low, the level-conversion circuit does not operate and stays in the standby state. In that state, the level-conversion circuit is controlled, so as to cut the sub-threshold leak current.
Description will be made of the second embodiment with reference to the circuit illustrated in FIG. 8 .
Where the level of the activation signal ACT is high, which means that the level of the non-activation signal/ACT is low, the transfer switch TG 2 is turned on and the transfer switch TG 1 is turned off. Since the signal node-N 1 is transmitted to each of the gates of the PMOS transistor MP 6 and the NMOS transistor MN 6 , the PMOS transistor MP 6 and the NMOS transistor MN 6 are turned on and off, as is the case with the PMOS transistor MP 3 and the NMOS transistor MN 3 . However, since the PMOS transistor MP 9 and the NMOS transistor MN 9 remain turned on and the PMOS transistor MP 3 and the NMOS transistor MN 3 are connected to their power sources, respectively, the circuit configuration and operations of this embodiment becomes the same as those of the first embodiment. Therefore, the operations of the level-conversion circuit of this embodiment will not be described.
Where the level of the activation signal ACT is low, which means that the level of the non-activation signal/ACT is high, the PMOS transistor MP 9 and the NMOS transistor MN 9 remain turned off, the transfer switch TG 2 including the PMOS transistor MP 7 and the NMOS transistor MN 7 remains turned off, and the transfer switch TG 1 including the PMOS transistor MP 8 and the NMOS transistor MN 8 remains turned on. A signal transmitted from the first-stage inverter circuit including the PMOS transistor MP 1 and the NMOS transistor MN 1 is interrupted, so that a short circuit occurs between the output OUT and the node N 1 . For example, where the level of the output OUT is low, the level of the signal node-N 1 becomes low, so that the signal node N 1 is transmitted to each of the gates of the PMOS transistors MP 6 and MP 3 , and the NMOS transistors MN 3 and MN 6 . The PMOS transistors MP 6 and MP 3 are turned on and the NMOS transistors MN 3 and MN 6 are turned off. Since the threshold value of the NMOS transistor MN 3 is low, the sub-threshold leak current may occur even though the NMOS transistor MN 3 is turned off. However, since the NMOS transistor MN 6 is turned off, no leak currents are generated between the power-source voltage VDD and the ground voltage VSS.
Further, where the level of the output OUT is high, the level of the signal node-N 1 becomes high so that the signal node N 1 is transmitted to each of the gates of the PMOS transistors MP 6 and MP 3 , and the NMOS transistors MN 3 and MN 6 . The PMOS transistors MP 6 and MP 3 are turned off and the NMOS transistors MN 3 and MN 6 are turned on. Since the threshold value of the PMOS transistor MP 3 is low, the sub-threshold leak current may occur even though the PMOS transistor MP 3 is turned off. However, since the PMOS transistor MP 6 is turned off, no leak currents are generated between the power-source voltage VDD and the ground voltage VSS.
Where the input signal IN is caused to transition and the ON state and OFF state of the NMOS transistor MN 4 and the PMOS transistor MP 4 are changed during the level-conversion circuit is in the standby state, either the PMOS transistor MP 6 or the NMOS transistor MN 6 between the power-source voltage VDD and the ground voltage VSS is turned off due to a signal transmitted from the output OUT. Therefore, the level of the node N 3 and/or the node N 4 is not changed and the output level stays in the latched state.
As described above, where the level-conversion circuit is in the standby state, the signal ACT is kept at the low level, which means that the signal/ACT is kept at the high level. Consequently, the sub-threshold leak currents can be cut while the output data is held. Although the signal OUT is fed back to the node N 1 in this embodiment, any signals that operate as the signal OUT does can be used, as the signal fed back to the node N 1 . Further, according to this embodiment, the PMOS transistors MP 6 and MP 9 , and the NMOS transistors MN 6 and MN 9 are provided, as the measures against the sub-threshold leak currents generated by the PMOS transistor MP 3 and the NMOS transistor MN 3 . However, where the PMOS transistor MP 3 and the NMOS transistor MN 3 generate no sub-threshold leak currents, the PMOS transistors MP 6 and MP 9 , and the NMOS transistors MN 6 and MN 9 are unnecessary.
This embodiment allows for cutting the sub-threshold leak currents that are generated, where the low voltage Vt is used for the above-described transistors. Therefore, the threshold value of the voltage Vt can be decreased, so as to be lower than that of the first embodiment. Thus, the operation speed of the level-conversion circuit of this embodiment can be further increased.
Third Embodiment
Next, a third embodiment of the present invention will now be described in detail with reference to FIGS. 9 and 10 . FIG. 9 shows an example level-conversion circuit of this embodiment. Although the output transistor including the PMOS transistor MP 5 and the NMOS transistor MN 5 of the first embodiment remains turned off except when the input change occurs, an output transistor including a PMOS transistor MP 12 and an NMOS transistor MN 12 of this embodiment is driven at all times. Accordingly, the level-conversion circuit of this embodiment does not require the above-described data-holding unit. The level-conversion circuit of this embodiment comprises an input terminal 1 to which an input signal IN is transmitted, a PMOS driver-control unit 402 , an NMOS driver-control unit 403 , a PMOS-side power-source control unit 404 , an NMOS-side power-source control unit 405 , the output transistors MP 12 and MN 12 , an output terminal 2 for outputting an output signal OUT, and an output-data feedback unit 406 .
The PMOS driver-control unit 402 comprises an NMOS transistor MN 11 , a PMOS transistor MP 10 , and a PMOS transistor MP 15 . The source of the NMOS transistor MN 11 is connected to a power source VSSH, the gate thereof is connected to the input signal IN, and the drain thereof is connected to a node N 5 . The drain of the PMOS transistor MP 10 is connected to the node N 5 , the gate thereof is connected to the output signal OUT, and the source thereof is connected to the drain of the PMOS transistor MP 15 . The drain of the PMOS transistor MP 15 is connected to the source of the PMOS transistor MP 10 , the gate thereof is connected to a ground voltage VSS, and the source thereof is connected to the power source VDD. Here, the NMOS transistor MN 11 is a transistor using a low voltage Vt.
Where the input signal IN is caused to transition from the level VSSH to the level VDDL, the NMOS transistor MN 11 is turned on and transmits a source potential VSSH to the node N 5 . The output signal OUT is a low-level output and the PMOS transistor MP 10 is turned on then. However, since the driving capacity of the PMOS transistor MP 15 connected to the source side of the PMOS transistor MP 10 is reduced, so as to be almost negligible in comparison with the driving capacity of the NMOS transistor MN 11 , the node N 5 is caused to transition to the level VSSH with high speed. Where the level of the output signal OUT is changed to a high level, the PMOS transistor MP 10 is turned off.
Where the input signal IN is caused to transition from the level VDDL to the level VSSH, the NMOS transistor NM 11 is turned off. At this time, the output signal OUT is a high-level output and the PMOS transistor MP 10 remains turned off. The node N 5 is maintained at the level VSSH. Since the output signal OUT is changed to a low-level output due to a signal transmitted from the NMOS driver-control unit 403 , the PMOS transistor MP 10 is turned on and the level of the node N 5 is changed to a high level.
The NMOS driver-control unit 403 comprises a PMOS transistor MP 11 , an NMOS transistor MN 10 , and an NMOS transistor MN 15 . The source of the PMOS transistor MP 11 is connected to the power source VDDL, the gate thereof is connected to the input signal IN, and the drain thereof is connected to a node N 6 . The drain of the NMOS transistor MN 10 is connected to the node N 6 , the gate thereof is connected to the output signal OUT, and the source thereof is connected to the drain of the NMOS transistor MN 15 . The drain of the NMOS transistor MN 15 is connected to the source of the NMOS transistor MN 10 , the gate thereof is connected to the power-source voltage VDD, and the source thereof is connected to the ground voltage VSS. Here, the PMOS transistor MP 11 is formed, as a transistor using a low voltage Vt.
Where the input signal IN is caused to transition from the level VSSH to the level VDDL, the PMOS transistor MP 11 is turned off. At this time, the output signal OUT is a low-level output, the NMOS transistor MN 10 remains turned off, and the node N 6 is maintained at the level VDDL. Since the output signal OUT is changed to a high-level output due to a signal transmitted from the PMOS driver-control unit 402 , the NMOS transistor MN 10 is turned on and the level of the node N 6 is changed to a low level.
Where the input signal IN is caused to transition from the level VDDL to the level VSSH, the PMOS transistor NP 11 is turned on, so that the node N 6 is charged to the high level VDDL. At this time, the output signal OUT is a high-level output and the NMOS transistor MN 10 remains turned on. However, since the driving capacity of the NMOS transistor MN 15 connected to the source side of the NMOS transistor MN 10 is reduced, so as to be almost negligible in comparison with the driving capacity of the PMOS transistor MP 11 , the node N 6 is caused to transition to the level VDDL with high speed. Where the level of the output signal OUT is changed to a low level, the NMOS transistor MN 10 is turned off.
The drain of the output transistor MP 12 is connected to the output signal OUT, the gate thereof is connected to the node N 5 , and the source thereof is connected to the drain of the PMOS transistor MP 13 . Further, the drain of the output transistor MN 12 is connected to the output signal OUT, the gate thereof is connected to the node N 6 , and the source thereof is connected to the drain of the NMOS transistor MN 13 .
The PMOS-side power-source control unit 404 includes a PMOS transistor MP 13 and a PMOS transistor MP 14 . The drain of the PMOS transistor MP 13 is connected to the source of the PMOS transistor MP 12 , the gate thereof is connected to a node N 7 , and the source thereof is connected to the power source VDD. The drain of the PMOS transistor MP 14 is connected to the source of the PMOS transistor MP 12 , the gate thereof is connected to a node N 8 , and the source thereof is connected to the power source VDD. A signal N 8 generated by delaying the output signal OUT is transmitted to the gate of the PMOS transistor MP 14 and a signal N 7 generated by inverting the output signal OUT is transmitted to the gate of the PMOS transistor MP 13 .
Where the input signal IN is caused to transition from the level VSSH to the level VDDL, the node N 5 is caused to transition from the level VDD to the level VSSH with high speed, the PMOS transistor MP 12 is turned on, and the level of the output signal OUT is increased to a high level with high speed. During the above-described transition occurs, the PMOS transistor MP 14 remains turned on and the PMOS transistor MP 13 remains turned off. Since a predetermined transistor satisfying expressions Ids (MP 14 )>>Ids (MP 13 ) and Ids (MP 12 )>>Ids (MP 13 ) is used, the PMOS transistor MP 14 remains turned on during the node N 5 is caused to transition. Subsequently, a large current is transmitted from the power source VDD and the output signal OUT is caused to transition to a high level with high speed. After the transition is finished and the output signal OUT is changed, the PMOS transistor MP 14 is turned off and the PMOS transistor MP 13 is turned on. Therefore, most of the current-supply capacity is lost, though data can be held therein.
Where the input signal IN is caused to transition from the level VDDL to the level VSSH, the node N 5 is caused to transition from the level VSSH to the level VDD. During the above-described transition occurs, the PMOS transistor MP 14 remains turned off and the PMOS transistor MP 13 remains turned on. Further, a short circuit occurs between the output OUT and the power source VDD via the PMOS transistors MP 12 and MP 13 . However, since most of the current-supply capacity is lost, the NMOS transistors MN 14 and MN 12 of the NMOS-side power-source control unit 405 are turned on, so that the output OUT is caused to transition to the low level with high speed. Due to the change to the low level, the PMOS transistor MP 10 of the PMOS driver-control unit 402 is turned on. Subsequently, the node N 5 is charged to the level VDD, and the PMOS transistor MP 12 is turned off.
The NMOS-side power-source control unit 405 comprises an NMOS transistor MN 13 and an NMOS transistor MN 14 . The drain of the NMOS transistor MN 13 is connected to the source of the NMOS transistor MN 12 , the gate thereof is connected to the node N 7 , and the source thereof is connected to the power source VSS. The drain of the NMOS transistor MN 14 is connected to the source of the NMOS transistor MN 12 , the gate thereof is connected to the node N 8 , and the source thereof is connected to the power source VSS. The signal N 8 generated by delaying the output signal OUT is transmitted to the gate of the NMOS transistor MN 14 and the signal N 7 generated by inverting the output signal OUT is transmitted to the gate of the NMOS transistor MN 13 .
Where the input signal IN is caused to transition from the level VSSH to the level VDDL, the node N 6 is caused to transition from the level VDDL to the level VSS. During the transition occurs, the NMOS transistor MN 14 remains turned off and the NMOS transistor MN 13 remains turned on. As is the case with the PMOS-side power-source control unit 404 , a predetermined transistor satisfying expressions Ids (MN 14 )>>Ids (MN 13 ) and Ids (MN 12 )>>Ids (MN 13 ) is used. Subsequently, a short circuit occurs between the output OUT and the power source VSS via the NMOS transistors MN 12 and MN 13 . However, since most of the current-supply capacity is lost, the PMOS transistors MP 14 and MN 12 of the PMOS-side power-source control unit 404 are turned on, so that the output signal OUT is caused to transition to the high level with high speed. Due to the transition to the high level, the NMOS transistor MN 10 of the NMOS driver-control unit 403 is turned on. Subsequently, a predetermined number of electrical charges are drawn from the node N 6 so that the level of the node N 6 is decreased to the level VSS and the NMOS transistor MN 12 is turned off.
Where the input signal IN is caused to transition from the level VDDL to the level VSSH, the PMOS transistor MP 11 is turned on, the node N 6 is caused to transition from the level VSS to the level VDDL with high speed, the NMOS transistor MN 12 is turned on, and the level of the output signal OUT is decreased to a low level with high speed. Since the NMOS transistor MN 14 remains turned on during the above-described transition occurs, a large current is supplied, so that the level of the output signal OUT becomes low. After the transition is finished and the output signal OUT is changed, the NMOS transistor MN 14 is turned off and the NMOS transistor MN 13 is turned on. Therefore, most of the current-supply capacity is lost, though data can be held therein.
The output-data feedback unit 406 includes an inverter circuit INV 3 and an inverter circuit INV 4 . An output signal OUT is input to the inverter circuit INV 3 . The inverter circuit INV 3 transmits an inverted signal N 7 . Upon receiving the inverted signal N 7 , the inverter circuit INV 4 delays and inverts the input signal, so as to generate and output the signal N 8 . Further, where the level of the output signal OUT is caused to transition from low to high, the node N 7 may preferably turn off the NMOS transistor MN 13 with high speed. Conversely, the node N 8 needs to be delayed, so as to turn off the PMOS transistor MP 17 after the transition of the output signal is finished. In this embodiment, the inverter INV 4 functions as delay means. However, the delay means may be achieved by known technologies, without being limited to the above-described one-stage inverter INV 4 .
In this embodiment, each of the PMOS driver-control unit 402 and the NMOS driver-control unit 403 can rise and fall with high speed. For example, where the NMOS transistor MN 11 is turned on, a current transmitted from the power source VDD to the node N 5 is negligible in comparison with a current drawn to the power source VSSH, so that the node N 5 is caused to transition with high speed. Further, where the PMOS transistor MP 12 is turned on, a current transmitted from the output OUT to the NMOS-side power-source control unit 405 is negligible in comparison with a current transmitted from the PMOS-side power-source control unit 404 . Therefore, through-current flows are hardly generated between the output transistors MP 12 and MN 12 . As a result, the output transistors MP 12 and MN 12 can operate with high speed. After the output transistors MP 12 and MN 12 operate, a current held by the output-data feedback unit 406 is transmitted. Subsequently, the same effect as that of the first embodiment is obtained.
As has been described, according to the configuration of the third embodiment, the on side of drive transistors is designed, so as to be ready for high speed, and the off-side thereof is designed, so as to be ready for low speed. However, since the power source of the driver transistors is controlled, so as to control an output, the same effect as that of the first embodiment can be obtained without using an output-data holding circuit.
Fourth Embodiment
Next, a fourth embodiment of the present invention will be described in detail with reference to FIG. 11 . This drawing shows an example level-conversion circuit of this embodiment. This level-conversion circuit has measures against a sub-threshold leak current, in comparison with the level-conversion circuit of the third embodiment. Further, where the level of a signal ACT that is an external control signal is high, the level-conversion circuit of this embodiment operates and accepts the sub-threshold leak current. Specifically, the level-conversion circuit of this embodiment accepts the sub-threshold leak current, where the level-conversion circuit is in an operation state. Conversely, where the level of the signal ACT is low, the level-conversion circuit does not operate. Specifically, the level-conversion circuit enters the standby state. In the standby state, the level-conversion circuit is controlled, so as to cut the sub-threshold leak current.
The level-conversion circuit of this embodiment is different from that of the third embodiment in that the inverted-activation signal/ACT is transmitted to the gate of the PMOS transistor MP 15 , the activation signal ACT is transmitted to the gate of the NMOS transistor MN 15 , and a signal node-N 9 is transmitted to each of the gates of the PMOS transistor MP 14 and the NMOS transistor MN 14 . Further, transfer switches TG 3 and TG 4 are added to the level-conversion circuit of this embodiment. The transfer switch TG 3 receives the signal node-N 7 , as an input signal, and is activated when the level of the inverted-activation signal/ACT is high, so as to transmit the signal node-N 7 to the node N 9 . The transfer switch TG 4 receives the signal node-N 8 , as an input signal, and is activated when the level of the activation signal ACT is high, so as to transmit the signal node-N 8 to the node N 9 .
In this embodiment, the activation signal ACT is transmitted to the NMOS transistor MN 15 , as an external control signal, and the inverted-activation signal/ACT is transmitted to the PMOS transistor MP 15 , as a control signal. Where the level of the activation signal ACT is high, the level-conversion circuit operates, as is the case with the third embodiment. However, where the level of the activation signal ACT is low, the level-conversion circuit enters the standby state, in which the PMOS transistor MP 15 and the NMOS transistor MN 15 are turned off so that currents are cut off. Further, where the level-conversion circuit is in the operation state, a signal node-N 8 is used, as a feedback signal transmitted to the PMOS transistor MP 14 and the NMOS transistor MN 14 . However, where the level-conversion circuit is in the standby state, a signal node-N 7 is used, as the feedback signal. Specifically, where the level-conversion circuit is in the standby state, the node N 7 is connected to each of the gates of the PMOS transistors MP 6 and MP 7 , and the NMOS transistors MN 6 and MN 7 .
Next, operations of the level-conversion circuit of this embodiment will be described. Where the level-conversion circuit is in the operation state (where the level of the activation signal ACT is high and that of the inverted-activation signal is low), the gate of the PMOS transistor MP 15 is maintained at a low level and the gate of the NMOS transistor MN 15 is maintained at a high level. The node N 9 is connected to the node N 8 and the transfer gate TG 2 is turned on. Since the connection and operations of this embodiment are the same as those of the third embodiment, the operations of this embodiment will not be described.
Where the level-conversion circuit is in the standby state (where the level of the activation signal ACT is low and that of the inverted-activation signal/ACT is high), the PMOS transistor MP 15 and the NMOS transistor MN 15 are turned off. Since low voltages Vt are used for the NMOS transistor MN 11 and the PMOS transistor MP 11 , the sub-threshold leak current may occur and a standby-leak current may increase, even though a gate-to-source voltage Vgs is 0 volt. However, since the PMOS transistor MP 15 and the NMOS transistor MN 15 are turned off by the inverted-activation signal/ACT and the activation signal ACT, current paths to the power source VDD and the power source VSS are cut, so that the PMOS and NMOS driver circuits generate no standby leak currents. Further, the transfer gate TG 3 is turned on, the node N 9 is connected to the node N 7 , and a signal transmitted from the node 7 is transmitted to each of the PMOS transistors MP 13 and MP 14 of the PMOS-side power-source control unit 404 and the NMOS transistors MN 13 and MN 14 of the NMOS-side power-source control unit 405 , so that either the transistors on the PMOS side or the transistors on the NMOS side are turned off. Therefore, as for the transistors of the output stage, either the current path to the power source VDD or the current path to the power source VSS is cut, so that the power-source control circuit generates no standby leak currents.
Where the level-conversion circuit is in the standby state (where the level of the activation signal ACT is low and that of the inverted-activation signal/ACT is high) and the input signal IN is caused to transition from the level VSSH to the level VDDL, the level-conversion circuit operates, as below. Where the input signal IN is caused to transition to the level VSSH, the PMOS transistor MP 11 is turned on, the node N 6 is at a high level, the NMOS transistors MN 12 , MN 13 , and MN 14 are turned on, and the output signal OUT at a low-level signal is transmitted. Where the input signal IN is caused to transition to the level VDDL, the PMOS transistor MP 11 is turned off, the NMOS transistor MN 11 is turned on, the level of the node N 5 becomes low, and the PMOS transistor MP 12 is turned on. Although the PMOS transistor MP 11 is turned off then, the NMOS transistors MN 10 and MN 15 are also turned off. Therefore, the node N 6 is maintained at the level VDDL, which is a high level, and the NMOS transistor MN 12 remains turned on. Subsequently, both the PMOS transistor MP 12 and the NMOS transistor MN 12 are turned on. The PMOS transistors MP 13 and MP 14 are turned off and the NMOS transistors MN 13 and MN 14 are turned on due to the output signal OUT. Further, the output signal is maintained at the low level, so that the previous output state is maintained. Further, since the PMOS transistor MP 11 , and the NMOS transistors MN 10 and MN 15 remain turned off, the node N 6 is floated. However, since the PMOS transistor MP 11 uses the low voltage Vt, the node N 6 is maintained at a high level due to the sub-threshold leak current.
Where the input signal IN is caused to transition from the level VDDL to the level VSSH, the level-conversion circuit operates, as below. Where the input signal IN is at the level VDDL, the NMOS transistor MN 11 is turned on, the node N 5 is maintained at a low level, the PMOS transistors MP 12 , MP 13 , and MP 14 are turned on, and the output signal OUT is at a high level. Where the input signal IN is caused to transition to the level VSSH, the NMOS transistor MN 11 is turned off and the PMOS transistor MP 11 is turned on, so that the level of the node N 6 becomes high and the NMOS transistor MN 12 is turned on. Although the NMOS transistor MN 11 is turned off then, the PMOS transistors MP 10 and MP 15 are also turned off. Therefore, the node N 5 is maintained at the VSSH level, which is a low level, and the PMOS transistor MP 12 remains turned on.
Consequently, both the PMOS transistor MP 12 and the NMOS transistor MN 12 are turned on. The PMOS transistors MP 13 and MP 14 are turned on and the NMOS transistors MN 13 and MN 14 are turned off due to the output signal OUT. Further, the output signal is maintained at the high level, so that the previous output state is maintained. Further, since the PMOS transistors MP 15 and MP 10 , and the NMOS transistor MN 11 remain turned off then, the node N 5 is floated. However, since the NMOS transistor MN 11 uses the low voltage Vt, the node N 5 is maintained at a low level due to the sub-threshold leak current.
As has been described, where the input signal IN is caused to transition to one level to another level during the level-conversion circuit is in the standby state, each of the gates of the PMOS transistors MP 13 and MP 14 , and those of the NMOS transistors MN 13 and MN 14 is connected to the node N 7 . Therefore, according to the previous state of the output signal OUT, the PMOS transistors MP 13 and MP 14 , and the NMOS transistors MN 13 and MN 14 remain turned on/off. Consequently, the output signal OUT remains in the previous output state. Further, even though each of the transfer gates TG 3 and TG 4 is formed, as a CMOS transfer gate, the configuration thereof may be modified, so long as it can generate the same signal as that of this embodiment.
Thus, this embodiment allows for cutting power supplied from the power sources by using a standby signal and feeding an output signal OUT back to an output-driver stage, so that the data-holding function for holding output data is achieved. Therefore, according to this embodiment, the sub-threshold leak current can be cut during the level-conversion circuit is in the standby state, even though the level-conversion circuit includes transistors using a low voltage Vt. Further, output data can be held when the sub-threshold leak is cut.
Fifth Embodiment
Next, a fifth embodiment of the present invention will be described in detail with reference to FIG. 12 . This drawing shows an example semiconductor circuit, wherein small-amplitude wiring is temporarily buffered between a driver circuit 700 and a level-conversion circuit 701 . In recent years, semiconductor circuits have become increasingly large scale and the small-amplitude wiring between circuits thereof has become increasingly long. Therefore, waveform shaping may preferably be performed midway through the semiconductor circuit. According to this embodiment, a small-amplitude signal transmitted from the driver circuit 700 is reshaped and amplified by a buffer circuit 702 , and transmitted to the level-conversion circuit 701 , as the small-amplitude signal. The buffer circuit 702 includes a level-conversion circuit 703 according to any one of the first to fourth embodiments and a driver unit 704 . Upon receiving an output signal transmitted from the level-conversion circuit 703 , the driver unit 704 transmits a small-amplitude-level signal.
The driver unit 704 of the buffer circuit 702 includes a PMOS transistor MP 16 and an NMOS transistor MN 16 . The output signal transmitted from the level-conversion circuit 703 is transmitted to each of the gates of the PMOS transistor MP 16 and the NMOS transistor MN 16 . The source of the PMOS transistor MP 16 is connected to the power source VDDL, and the source of the NMOS transistor MN 16 is connected to the power source VSSH. The drains of the PMOS transistor MP 16 and the NMOS transistor MN 16 function, as an output end of the buffer circuit 702 . The level-conversion circuit 703 converts an input signal with a small amplitude VDDL to VSSH into a signal with an amplitude VDD to VSS. Upon receiving the VDD-to-VSS amplitude signal, the driver unit 704 transmits the signal, as the VDDL-to-VSSH small-amplitude signal again. Thus, since the buffer circuit 702 is provided, the wiring between the circuits forming the semiconductor circuit can be divided and the signal can be reshaped. Accordingly, the semiconductor circuit can transmit signals with high speed and precision.
As has been described, the semiconductor circuit of this embodiment includes the buffer circuit 702 for receiving a small-amplitude signal midway through the long wiring so that the small-amplitude signal is converted into a full-amplitude signal and further converted into the small-amplitude signal again. Accordingly, the small-amplitude signal can operate with high speed on the rising and/or falling edge, even though the wiring length increases.
Thus, the embodiments of the present invention have been described in detail. However, the present invention is not limited to the above-described embodiments, but can be modified in various ways without leaving the scope of the appended claims. For example, though the small-amplitude level of a signal transmitted from the driver circuit has been described as the level VDDL and the level VSSH, the small-amplitude level shown in FIGS. 8 and 9 may be changed to the level VDDL and the level VSS, or the level VDD and the level VSSH. | An independent control signal is transmitted to each of a driver control unit and an output transistor, so as to prevent the driver control unit and the output transistor from being made to operate at the same time and reduce through-current flows. Since the transistor ratio can be selected easily, the degree of designing flexibility increases and the speed enhancement is achieved. | 72,640 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit of provisional application No. 61/309,389 (Attorney Docket No. 19744P-003800US), filed on Mar. 1, 2010, and of provisional application No. 61/385,637 (Attorney Docket No. 19744P-004000US), filed on Sep. 28, 2010, the full disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to medical devices and methods. More particularly, the present invention relates to apparatus for accessing vascular lumens and methods for clearing vascular lumens of occlusive materials.
[0004] Removing occlusive materials from the vasculature and other body lumens is the objective of many medical procedures. Obstructive materials in the vasculature include plaque, thrombus, embolus, clots, and fatty deposits. To remove such occlusive materials, catheters may be inserted into the occluded artery or vein for opening or removing the occlusive material. Of particular interest to the present invention, procedures commonly referred to as thrombectomy or embolectomy use a balloon-tipped catheter which is inserted into a blood vessel, either percutaneously or via a surgical cut down, where the balloon is advanced to a position distal to the obstructing material. After inflating the balloon, the catheter is drawn proximally to dislodge the material and remove it from the blood vessel. In some instances, a second sheath or catheter is introduced coaxially over the balloon-tipped catheter in order to apply suction and help remove the occlusive material before it is drawn out of the blood vessel.
[0005] When performing such thrombectomy or embolectomy procedures, the balloon-tipped catheters and other auxiliary tools may be introduced through a sheath which is positioned through a percutaneous tissue tract to allow access to the blood vessel. In addition, other auxiliary sheaths and tubular catheters may be employed and other aspects of the thrombectomy, embolectomy, or other vascular procedures.
[0006] While very effective, thrombectomy and embolectomy procedures sometimes have difficulty dislodging and removing certain occlusive materials from certain types of vessels. For example, the use of thrombectomy for removing plaque, clot and other occlusive buildups in arterio-venous grafts (AVG's) and arterio-venous fistulas (AVF's) can be particularly problematic. For example, a plug of occlusive materials frequently forms at the anastomosis site between the artery and vein, or artery and graft, and can be very difficult to remove. Moreover, the access sheaths and capture devices used in such procedures are not always optimal.
[0007] For these reasons, it would be desirable to provide improved methods and apparatus for performing thrombectomy and embolectomy procedures. It would be particularly desirable if such catheters and devices could improve the capture of clot, plaque, and other occlusive materials from AVG's and AVF's. Improved sheaths and other auxiliary devices for performing those procedures and others would also be desirable. At least some of these objectives will be met by the inventions described below.
[0008] 2. Description of the Background Art
[0009] Thrombectomy devices employing aspiration are described in U.S. Pat. No. 6,292,633; U.S. 2002/0169436; U.S. Pat. No. 7,141,045; U.S. Pat. No. 7,033,344; U.S. Pat. No. 6,544,276; U.S. Pat. No. 7,578,830; U.S. Pat. No. 6,695,858; U.S. Pat. No. 6,210,370; U.S. Pat. No. 5,102,415; and U.S. Pat. No. 5,092,839. Catheters and sheaths having self-expanding regions are described in U.S. 2010/0131000; U.S. 2007/0135832; U.S. Pat. No. 7,799,046; U.S. Pat. No. 7,410,491; U.S. Pat. No. 6,511,492; U.S. Pat. No.6,159,230 and U.S. Pat. No. 5,971,938.
SUMMARY OF THE INVENTION
[0010] One embodiment of the present radially collapsible and expandable sheath is configured for introducing an intravascular device into a patient's vasculature through a percutaneous access site. The sheath comprises an elongate, elastomeric, tubular casing including an inner layer and an outer layer defining an annular space therebetween. The casing has a distal end. The sheath further comprises an elongate wire. At least a portion of the wire occupies the annular space and forms a helix around the casing inner layer. The helix includes a plurality of coils. A distally directed force applied to the wire decreases a pitch between adjacent ones of the coils and radially expands the helix and the casing. A proximally directed force applied to the wire increases the pitch between adjacent ones of the coils and radially contracts the helix and the casing.
[0011] One embodiment of the present radially collapsible and expandable intravascular device is configured for removing a thrombus from a patient's vasculature through a percutaneous access site. The device comprises an elongate tubular catheter having a distal end. The device further comprises an elongate, elastomeric, tubular casing surrounding at least a portion of the catheter. The casing is secured to the catheter at or near the catheter distal end. The device further comprises an elongate wire. At least a portion of the wire occupies a space between the catheter and the casing and forms a helix around the catheter. The helix includes a plurality of coils. A distally directed force applied to the wire decreases a pitch between adjacent ones of the coils and radially expands the helix and the casing. A proximally directed force applied to the wire increases the pitch between adjacent ones of the coils and radially contracts the helix and the casing.
[0012] One embodiment comprises a system for removing a thrombus from a patient's vasculature through a percutaneous access site. The system includes the sheath described above in combination with the thrombus collection device described above.
[0013] One embodiment of the present methods for emplacing a radially collapsible and expandable sheath into a patient's vasculature through a percutaneous access site comprises a sheath including an elongate, elastomeric, tubular casing including an inner layer and an outer layer defining an annular space therebetween. The sheath further comprises an elongate wire, at least a portion of the wire occupying the annular space and forming a helix around the casing inner layer, the helix including a plurality of coils. The method comprises puncturing the patient's skin and vasculature with a catheter delivery needle in order to dispose a catheter within the patient's vasculature with a proximal end of the catheter protruding from the percutaneous access site. The method further comprises withdrawing the delivery needle. The method further comprises introducing the sheath, in a collapsed state, into the vasculature through a hollow lumen of the catheter. The method further comprises applying a distally directed force to the wire to decrease a pitch between adjacent ones of the coils and radially expand the helix and the casing so that the casing contacts interior walls of the vasculature. In certain embodiments, the method may further comprise applying a proximally directed force to the wire to increase a pitch between adjacent ones of the coils and radially collapse the helix and the casing.
[0014] One embodiment of the present methods for extracting a thrombus from a patient's vasculature through a percutaneous access site using a radially collapsible and expandable thrombus collection device comprises the device including an elongate tubular catheter having a distal end, an elongate, elastomeric, tubular casing surrounding at least a portion of the catheter. The device further comprises an elongate wire, at least a portion of the wire occupying a space between the catheter and the casing and forming a helix around the catheter, the helix including a plurality of coils. The method comprises emplacing a percutaneous introducer sheath into the patient's vasculature. The method further comprises introducing the thrombus collection device, in a collapsed state, by passing it through the sheath and into the patient's vasculature. The method further comprises advancing the device through the patient's vasculature toward a location of the thrombus by applying a distally directed force to a portion of the catheter that protrudes from the percutaneous access site. The method further comprises continuing to apply the distally directed force to push a distal end of the device through the thrombus. The method further comprises advancing the device through the thrombus until the casing has completely passed through the thrombus. The method further comprises expanding the wire and the casing by applying a distally directed force to the wire while holding the catheter stationary until at least a proximal end of the casing contacts an interior diameter of the vasculature. The method further comprises drawing the device back through the vasculature by applying a proximally directed force to the catheter while holding the wire stationary with respect to the catheter to maintain the casing in its expanded state. The method further comprises collecting the thrombus and trapping it within the space between the casing and the catheter as the device is drawn back. The method further comprises continuing to pull back on the catheter until the thrombus collection device reaches the distal end of the sheath. The method further comprises drawing the device through the sheath, together with the collected thrombus, until the device and the thrombus are completely extracted from the patient; and withdrawing the sheath from the percutaneous access site.
[0015] Another embodiment of the present methods for extracting a thrombus from a patient's vasculature through a percutaneous access site using a radially collapsible and expandable sheath and a radially collapsible and expandable thrombus collection device comprises the sheath including an elongate, elastomeric, tubular casing including an inner layer and an outer layer defining an annular space therebetween. The sheath further comprises an elongate wire, at least a portion of the sheath wire occupying the annular space and forming a helix around the casing inner layer, the sheath helix including a plurality of coils. The thrombus collection device includes an elongate tubular catheter having a distal end, an elongate, elastomeric, tubular casing surrounding at least a portion of the catheter, and an elongate wire. At least a portion of the device wire occupies a space between the catheter and the device casing and forms a helix around the catheter, the device helix including a plurality of coils. The method comprises puncturing the patient's skin and vasculature with a catheter delivery needle in order to dispose a delivery catheter within the patient's vasculature with a proximal end of the delivery catheter protruding from the percutaneous access site. The method further comprises withdrawing the delivery needle. The method further comprises introducing the sheath, in a collapsed state, into the vasculature through a hollow lumen of the delivery catheter. The method further comprises applying a distally directed force to the sheath wire to decrease a pitch between adjacent ones of the sheath coils and radially expand the sheath helix and the sheath casing so that the sheath casing contacts interior walls of the vasculature. The method further comprises introducing the thrombus collection device, in a collapsed state, by passing it through the sheath and into the patient's vasculature. The method further comprises advancing the device through the patient's vasculature toward a location of the thrombus by applying a distally directed force to a portion of the device catheter that protrudes from the percutaneous access site. The method further comprises continuing to apply the distally directed force to push a distal end of the device through the thrombus. The method further comprises advancing the device through the thrombus until the device casing has completely passed through the thrombus. The method further comprises expanding the device wire and the device casing by applying a distally directed force to the device wire while holding the device catheter stationary until at least a proximal end of the device casing contacts an interior diameter of the vasculature. The method further comprises drawing the device back through the vasculature by applying a proximally directed force to the device catheter while holding the device wire stationary with respect to the device catheter to maintain the device casing in its expanded state. The method further comprises collecting the thrombus and trapping it within the space between the device casing and the device catheter as the device is drawn back. The method further comprises continuing to pull back on the device catheter until the thrombus collection device reaches the distal end of the sheath. The method further comprises drawing the device through the sheath, together with the collected thrombus, until the device and the thrombus are completely extracted from the patient. The method further comprises applying a proximally directed force to the sheath wire to increase a pitch between adjacent ones of the sheath coils and radially collapse the sheath helix and the sheath casing. The method further comprises withdrawing the sheath from the percutaneous access site.
[0016] Another embodiment of the present introducer sheaths is configured for introducing an intravascular device into a patient's vasculature through a percutaneous access site. The sheath is elongate, tubular, and defines a sheath lumen. The sheath comprises a medial neck portion that flares outwardly to a wider bell portion at a distal end. The distal end of the bell portion is open. The neck portion and the bell portion comprise a compliant material. The bell portion of the sheath includes a wire that is encased within the compliant material. The wire supports the compliant material, maintaining the bell portion in its expanded shape when the sheath is unstressed. At a proximal end, the sheath includes a flush port that enables fluid to be injected and/or aspirated from the sheath lumen. Once deployed within the vasculature, a hemostasis valve at the proximal end of the sheath resists outflow of bodily fluids through the sheath.
[0017] One of the present embodiments comprises a deployment apparatus for an introducer sheath. The deployment apparatus includes a tubular dilator that is a rigid or semi-rigid component configured to guide the deployment apparatus through a skin puncture and through the vasculature. The dilator includes a proximal handle, a conically shaped distal tip, and defines a lumen that extends between the proximal and distal ends. The lumen is configured to receive a guide wire to facilitate introduction of the dilator into a patient. The introducer sheath is disposed coaxially about the outside of the dilator. An outer sheath is disposed coaxially about the outside of the introducer sheath. The outer sheath radially compresses the bell portion, which facilitates introduction of the sheath into the patient. The outer sheath is a tearaway sheath that can be torn by hand.
[0018] Another embodiment of the present methods comprises a method for deploying an introducer sheath in a patient's vasculature at a percutaneous access site using a deployment apparatus. The access site is prepared by puncturing the skin, any underlying tissue, and the vasculature with a needle. The operator then introduces a guide wire through the lumen of the needle, and withdraws the needle. The method further comprises the operator introducing the deployment apparatus into the vasculature through the puncture site using the guide wire. The operator advances the apparatus through the puncture site and the vasculature until a bell portion of the sheath is located entirely within the vasculature and a neck portion traverses the puncture site. The operator next removes a tearaway outer sheath from the deployment apparatus and pulls the outer sheath through the puncture site. The operator then removes a dilator of the apparatus.
[0019] Another embodiment of the present intravascular devices is configured for removing a thrombus from a patient's vasculature through a percutaneous access site. The device comprises an aspiration catheter including an elongate body having a balloon at its distal end. The catheter body comprises a flexible material having sufficient rigidity to facilitate guiding the catheter through the vasculature from the proximal end. The body defines two radially spaced lumens that are not in fluid communication with one another. The first lumen is an aspiration lumen that extends from an aspiration connector at the proximal end of the catheter to a plurality of aspiration openings toward the distal end of the catheter. The second lumen is an inflation lumen that extends from an inflation connector at the proximal end of the catheter to the balloon toward the distal end of the catheter. The aspiration lumen has a larger diameter than the inflation lumen, and is configured for passage of thrombus.
[0020] Another embodiment of the present methods comprises a method for percutaneously removing a thrombus from a patient's vasculature. The method comprises introducing an aspiration catheter into a patient's vasculature through an introducer sheath. The aspiration catheter is then advanced distally through the sheath, the vasculature, and the thrombus until a balloon of the catheter is disposed on the far side of the thrombus. A guide wire may be used to advance the catheter. The method further comprises connecting a syringe filled with inflation liquid to an inflation connector of the catheter. The operator depresses the syringe plunger to force the inflation liquid into the balloon through an inflation lumen. The operator inflates the balloon until it presses against the interior walls of the vasculature on the far side of the thrombus. The operator moves a stopcock to a position to prevent liquid flow through the inflation connector and disconnects the syringe from the stopcock. The operator removes the thrombus from the vasculature by using a combination of suction through the aspiration openings, and proximal movement of the inflated balloon across the thrombus. To do so, the operator connects a Luer stopcock to an aspiration connector and an empty syringe to the stopcock. To generate suction, the operator draws back on the syringe plunger with the stopcock in the closed position and then locks the plunger. The operator then draws the catheter out of the vasculature while simultaneously moving the stopcock to the open position, thereby exposing the vacuum in the syringe barrel to the aspiration lumen, generating suction that pulls pieces of the thrombus into the aspiration lumen through the aspiration openings. The operator continues to pull back on the aspiration catheter until all or substantially all of the thrombus has been pulled into the sheath. The operator then continues to pull back on the aspiration catheter to force the thrombus out of the vasculature through the sheath.
[0021] Thus, in a first aspect of the present invention, a sheath comprises a tubular body having a proximal, a distal end, and an axial passage therethrough. The tubular body is formed at least partially from an elastomeric material so that it can be collapsed, be expanded to a fully open configuration where it has an open diameter, and be further expanded beyond the open diameter by applying a radially outward force to an internal surface of the tubular body. The sheath further comprises a self-expanding scaffold coupled to at least a portion of the tubular body. The self-expanding scaffold also has a collapsed configuration, an expanded diameter when free from external constraint, and a super-expanded diameter or width when subject to a radially outward inner force. The expanded diameter of the self-expanding scaffold will be at least as large as the open diameter of the tubular body, optionally being larger. In this way, the scaffold will be able to open the tubular body. For example, the scaffold could be present only at the distal end of the tubular body so that said distal end will remain open while the remainder of the tubular body could remain in a collapsed configuration.
[0022] Optionally, the sheath will further comprise a shaft extending from the proximal end of the tubular body. In many instances, the shaft will comprise an extension of the scaffold. For example, the scaffold may be in the form of a helical coil where the shaft is an integral extension of the coil. That is, the shaft and coil may be formed from a single wire, filament, bundle or other structure where only a distal portion of the structure is formed into the coil to act as the scaffold while the remaining proximal portion of the structure can act as the shaft.
[0023] In most instances, the scaffold will have a cylindrical geometry when expanded, but in other instances the scaffold may have a tapered geometry when expanded. For example, the scaffold may be configured so that it tapers to a more narrow configuration in the distal direction. In such instances, the scaffold can form the tubular body into a capturing element for withdrawing clot.
[0024] In still other embodiments, the sheath may further comprise a catheter body where the sheath and scaffold are disposed over a distal end of the catheter body. Optionally, a shaft of the sheath may then extend through a lumen of the catheter body to allow selective opening and closing of the sheath over the catheter by translating the shaft forwardly or distally.
[0025] In specific embodiments, the self-expanding scaffold may be embedded in a wall of the sheath. Alternatively, the self-expanding scaffold may be secured to an inner or outer surface of a wall of the sheath. In a still further alternative embodiment, the self-expanding scaffold may be disposed in an annular space formed or created in a wall of the sheath so that the scaffold can foreshorten as it expands without constricting or deforming the wall (other than any radial expansion that may occur).
[0026] The sheath will have dimensions typical for medical sheaths. Typically, the tubular body will have an expanded diameter in the range from 3 Fr. to 24 Fr., the self-expanding scaffold will have a diameter in the range from 3 Fr. to 38 Fr. and the sheath will have a length in the range from 10 cms to 200 cms.
[0027] In a further aspect of the present invention, methods for aspirating occlusive material from a patient's vasculature comprise providing a catheter including a shaft, an expandable member at a distal end of the shaft, and an aspiration port on the shaft proximal to the expandable member. The aspiration port is connected to an aspiration lumen extending to a proximal end of the shaft. The catheter is introduced to a blood vessel (including implanted grafts and created fistulas) so that the expandable member lies on a distal side of the occlusive material. The expandable member is then expanded, and the catheter is drawn proximal while aspirating through the lumen end port to remove the occlusive material from the vessel. The methods of the present invention may be used in any blood vessel, but will find particular use with peripheral blood vessels, arterio-venous grafts, arterio-venous fistulas, and the like.
[0028] In the preferred embodiments, the catheter will consist of only a single balloon at a distal end of the catheter shaft and further preferably will consist of only a single aspiration port located proximally of the balloon, typically at a distance from 5 millimeters to 3 cms. Usually, the drawing and aspiration steps are performed simultaneously and are able together to remove substantially all the occlusive material. In other instances, however, some portion of the occlusive material will be drawn proximally without being aspirated through the port and lumen and will be removed from the vessel, graft, or fistula through an access sheath and/or a capturing catheter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 is a cross-sectional end view of one embodiment of the present radially collapsible and expandable introducer sheath, taken along the line 1 - 1 in FIG. 3 , and illustrating the sheath in a collapsed state;
[0030] FIG. 2 is a cross-sectional side view of the sheath of FIG. 1 , taken along the line 2 - 2 in FIG. 3 ;
[0031] FIG. 3 is an end/side perspective view of the sheath of FIG. 1 ;
[0032] FIG. 4 is a cross-sectional side view of the sheath of FIG. 1 , taken along the line 4 - 4 in FIG. 5 , and illustrating the sheath in an expanded state;
[0033] FIG. 5 is an end/side perspective view of the sheath of FIG. 4 ;
[0034] FIG. 6 is a partial cross-sectional side view of the sheath of FIGS. 1-5 disposed in a patient's vasculature at a percutaneous access site;
[0035] FIG. 7 is a side elevation view of one embodiment of the present collapsible and expandable thrombus collection device, illustrating the device in a collapsed state;
[0036] FIG. 8 is an end/side perspective view of the device of FIG. 7 ;
[0037] FIG. 9 is a side elevation view of the device of FIG. 7 , illustrating the device in an expanded state;
[0038] FIG. 10 is an end/side perspective view of the device of FIG. 9 ;
[0039] FIG. 11 is a partial cross-sectional side view of the sheath of FIGS. 1-6 in combination with the device of FIGS. 7-10 ;
[0040] FIG. 12 is a partial cross-sectional side view of the device of FIGS. 7-10 disposed in a patient's vasculature during a thrombectomy procedure;
[0041] FIG. 13 is a partial cross-sectional side view of the device of FIGS. 7-10 disposed in a patient's vasculature during a thrombectomy procedure;
[0042] FIG. 14 is a partial cross-sectional side view of the device of FIGS. 7-10 disposed in a patient's vasculature during a thrombectomy procedure;
[0043] FIG. 15 is a partial cross-sectional side view of the device of FIGS. 7-10 disposed in a patient's vasculature during a thrombectomy procedure;
[0044] FIG. 16 is a cross-sectional side view of another embodiment of the present radially collapsible and expandable introducer sheath;
[0045] FIG. 17 is a cross-sectional side view of another embodiment of the present radially collapsible and expandable thrombus collection device;
[0046] FIG. 18 is a side elevation view of another embodiment of the present introducer sheath;
[0047] FIG. 19 is a side elevation view of one embodiment of a deployment apparatus for the introducer sheath of FIG. 18 ;
[0048] FIG. 20 is a side cross-sectional view of the deployment apparatus of FIG. 19 ;
[0049] FIGS. 21-24 are side elevation views of one embodiment of steps for deploying the introducer sheath of FIG. 18 in a patient's vasculature at a percutaneous access site;
[0050] FIG. 25 is a side elevation view of one embodiment of the present thrombus collection device having aspiration ports;
[0051] FIG. 26 is a cross-sectional end view of the thrombus collection device of FIG. 25 , taken along the line 26 - 26 in FIG. 25 ;
[0052] FIGS. 27 and 28 are side elevation views of the proximal portions and distal portions, respectively, of the introducer sheath of FIG. 18 and the thrombus collection device of FIG. 25 during one step of a percutaneous thrombus collection procedure;
[0053] FIGS. 29 and 30 are side elevation views of the proximal portions and distal portions, respectively, of the introducer sheath of FIG. 18 and the thrombus collection device of FIG. 25 during another step of a percutaneous thrombus collection procedure;
[0054] FIGS. 31 and 32 are side elevation views of the proximal portions and distal portions, respectively, of the introducer sheath of FIG. 18 and the thrombus collection device of FIG. 25 during another step of a percutaneous thrombus collection procedure;
[0055] FIGS. 33 and 34 are side elevation views of the proximal portions and distal portions, respectively, of the introducer sheath of FIG. 18 and the thrombus collection device of FIG. 25 during another step of a percutaneous thrombus collection procedure;
[0056] FIG. 35 is a side elevation view of the introducer sheath of FIG. 18 after withdrawal from a patient's vasculature during another step of a percutaneous thrombus collection procedure;
[0057] FIG. 36 is a side elevation view of another embodiment of the present thrombus collection device having aspiration ports;
[0058] FIG. 37 is a side elevation view of the introducer sheath of FIG. 18 and a Fogarty balloon catheter disposed in a patient's vasculature during a percutaneous thrombus collection procedure;
[0059] FIG. 38 is a side elevation view of the introducer sheath of FIG. 18 and the thrombus collection device of FIGS. 7-10 disposed in a patient's vasculature during a percutaneous thrombus collection procedure; and
[0060] FIG. 39 is a side elevation view of a standard balloon catheter introducer sheath and the aspiration catheter of FIG. 25 disposed in a patient's vasculature during a percutaneous thrombus collection procedure.
DETAILED DESCRIPTION OF THE INVENTION
[0061] The following detailed description describes the present embodiments with reference to the drawings. In the drawings, reference numbers label elements of the present embodiments. These reference numbers are reproduced below in connection with the discussion of the corresponding drawing features. The various embodiments of the present introducer sheaths, thrombus collection devices and associated methods now will be discussed in detail. These embodiments include the introducer sheaths and thrombus collection devices shown in the accompanying drawings, which are for illustrative purposes only. These drawings include the following figures, in which like numerals indicate like parts:
[0062] Some embodiments of the present introducer sheaths, thrombus collection devices and associated methods are described below with reference to the figures. These figures, and their written descriptions, indicate that certain components of the apparatus are formed integrally, and certain other components are formed as separate pieces. Components shown and described herein as being formed integrally may in alternative embodiments be formed as separate pieces. Components shown and described herein as being formed as separate pieces may in alternative embodiments be formed integrally. Further, as used herein the term integral describes a single unitary piece.
[0063] FIGS. 1-6 illustrate one embodiment of the present radially collapsible and expandable sheath 20 . As shown in FIG. 6 , the sheath 20 is configured for passage into a patient's vasculature 22 (e.g. in a vein or artery, an arterio-venous fistula (AVF) or arterio-venous graft (AVG), or alternatively in a non-vascular location such as the peritoneal cavity or other bodily cavities or hollow anatomical structures) through an opening 24 at a percutaneous access site 26 . Once deployed as shown in FIG. 6 , the sheath 20 can be used as a conduit for introducing one or more intravascular devices into the patient's vasculature 22 . For example, and as discussed further below, in one embodiment the sheath 20 can be used to introduce a thrombectomy device.
[0064] FIGS. 1-3 illustrate the sheath 20 in a collapsed or contracted state. FIGS. 4 and 5 illustrate the sheath 20 in an expanded state. An operator may readily expand and contract the sheath 20 in the radial direction to increase or decrease its internal diameter 28 , 28 ′, respectively. For example, the internal diameter 28 , 28 ′ may be increased for the passage of intravascular devices, and decreased to promote hemostasis at the percutaneous access site 26 , as discussed further below.
[0065] With reference to FIGS. 1-3 , the sheath 20 comprises an elongate, elastomeric, tubular casing 30 . As shown in the cross-sectional views of FIGS. 1 and 2 , the tubular casing 30 includes an inner layer 32 and an outer layer 34 . The layers 32 , 34 define an annular space 36 between them. The annular space 36 receives a portion of an elongate wire 38 that an operator may manipulate to expand and contract the casing 30 , as described in detail below.
[0066] With particular reference to FIG. 2 , a distal end 40 of the wire 38 is disposed within the annular space 36 at or near a distal end 42 of the casing 30 . In one embodiment, the distal end 40 of the wire 38 may be secured to the casing 30 . In an alternative embodiment, the distal end 40 of the wire 38 may be freely movable with respect to the inner layer 32 and the outer layer 34 . The distal end 40 of the wire 38 may include a blunt cap (not shown) to reduce the likelihood of the wire 38 puncturing the elastomeric casing 30 .
[0067] Proximal of the wire 38 distal end 40 , the wire 38 forms a helix 44 . The helix 44 includes a plurality of coils 46 that wrap around the casing inner layer 32 beneath the casing outer layer 34 . The helix 44 extends to a proximal end 48 of the casing 30 where the wire 38 extends through an opening 50 in the casing 30 . As indicated by the break lines in FIGS. 2 and 3 , the wire 38 may have any desired length extending proximally of the casing 30 . As explained in further detail below, an operator may manipulate the proximal end of the wire 38 to force more of the wire 38 into the annular space 36 through the opening 50 , or to withdraw some of the wire 38 from the annular space 36 through the opening 50 . This manipulation expands and contracts the helix 44 and the casing 30 , as described below.
[0068] As described above, the casing 30 may comprise a compliant material. As used herein, the term compliant should be understood to include at least the following properties: flexibility, elasticity, and collapsibility/expandability. Further, because the casing 30 is configured for use internally, the material is preferably biocompatible. Example materials for the casing 30 include silicone film, polyisoprene, TECOTHANE®, PELLETHANE®, and other materials having similar properties.
[0069] The wire 38 preferably comprises a material that is flexible but incompressible. Further, because the wire 38 is configured for use internally, the material is preferably biocompatible. Example materials for the wire 38 include nickel-titanium (NiTi) alloys, stainless steel, polyether ether ketone (PEEK) and other materials having similar properties.
[0070] Again, FIGS. 1-3 illustrate the sheath 20 in a collapsed or contracted state. In this state, a relatively small portion of the wire 38 is disposed within the annular space 36 . However, when the flexible but incompressible wire 38 is subjected to a compressive force applied proximally of the casing 30 , wire 38 is forced into the annular space 36 through the opening 50 where the wire 38 enters the casing 30 . As more wire 38 enters the annular space 36 , the wire 38 forms tighter and more closely-spaced coils 46 within the helix 44 , with the coils 46 having increasingly larger diameters, as shown in FIGS. 4 and 5 . The elastomeric nature of the casing 30 makes it readily expandable in the radial direction as the wire 38 forces it outward. Similarly, when the wire 38 is subjected to a tensile force applied proximally of the opening 50 , the coils 46 within the helix 44 relax and spread apart as wire 38 is drawn out of the opening 50 . Again, the elastomeric nature of the casing 30 makes it readily contractible in the radial direction as the radial support provided by the wire 38 diminishes.
[0071] In the illustrated embodiment, the wire 38 is freely slidable within the annular space 36 with respect to the inner layer 32 and the outer layer 34 . Thus, as the wire 38 is forced into the annular space 36 through the opening 50 , the helix 44 slides against the inner and outer layers 32 , 34 to enable the casing 30 to expand without forming pleats between adjacent coils 46 . The expanded sheath 20 thus presents a relatively smooth inner diameter 28 ′ for easy passage of intravascular devices. However, in alternative embodiments the wire 38 may be secured to the casing 30 at one or more locations.
[0072] As shown in FIGS. 2 and 4 , the inner and outer layers 32 , 34 of the casing 30 preferably converge at the proximal end 52 , and at the distal end 42 , thereby sealing the proximal and distal ends 42 , 52 of the annular space 36 . The inner and outer layers 32 , 34 may, for example, be formed integrally. The sealed proximal end 52 of the annular space 36 facilitates controlled insertion and withdrawal of the wire 38 through the opening 50 . The sealed distal end 42 of the annular space 36 resists movement of the wire 38 distally out of the annular space 36 . The sealed distal end 42 can also form a smooth, atraumatic leading edge of the casing 30 to facilitate transport of material into the distal opening of the sheath 20 while avoiding injury to blood vessel walls or other nearby anatomy.
[0073] FIG. 6 illustrates the sheath 20 positioned in a patient's vasculature 22 through an opening 24 at a percutaneous access site 26 . The sheath 20 may be deployed in this configuration using, for example, a catheter (not shown). An operator may puncture the patient's skin 54 and vasculature 22 with a catheter delivery needle (not shown) in order to dispose the catheter within the patient's vasculature 22 with a proximal end of the catheter protruding from the percutaneous access site 26 , e.g. via the Seldinger technique or any other suitable access technique. The operator may then introduce the sheath 20 into the vasculature 22 through the catheter lumen and then withdraw the catheter over the sheath 20 , leaving the sheath 20 in the state shown in FIG. 6 . Alternatively, the operator can insert the sheath 20 over a guidewire emplaced via the Seldinger technique. For ease of insertion, the operator would typically introduce the sheath 20 in its collapsed state ( FIGS. 1-3 ). Upon emplacement, the operator may thereafter expand the sheath 20 to the configuration shown in FIG. 6 so that it achieves wall-to-wall apposition with the interior walls 56 of the vasculature 22 . The operator expands the sheath 20 by applying a distally directed force to the wire 38 as described above. Further expansion of the sheath 20 may facilitate removing thrombus from the vasculature 22 , as explained further below.
[0074] Once the sheath 20 is emplaced as shown in FIG. 6 , it is configured to provide an access path to the vasculature 22 for various intravascular devices. In one procedure described below, the sheath 20 is used to introduce a device for removing a thrombus. The sheath 20 can be used as an introducer for any type of intravascular device. The example described below is not limiting.
[0075] The expandable and contractible nature of the sheath 20 allows it to accommodate devices of various sizes. For example, the sheath 20 may be expanded to such an extent that it also radially expands the vasculature 22 , allowing for passage of a particularly large device or thrombus. Further, when another device is not disposed through the interior of the sheath 20 , the sheath 20 may be contracted to tighten the percutaneous access opening 24 . This contraction aids hemostasis, reducing the tendency of blood to flow outward from the percutaneous access opening 24 . The contraction can occur “automatically” without requiring action by the operator, resulting from the natural compliance and collapsibility of the sheath. The subcutaneous tissues surrounding the sheath 20 can exert sufficient pressure on the sheath 20 to contract the sheath and/or force it closed entirely, or otherwise force the sheath walls into close contact with any object(s) in the sheath lumen. When the intravascular procedure is complete, the operator may contract the sheath 20 and withdraw it from the percutaneous access opening 24 . The operator contracts the sheath 20 by applying a proximally directed force to the wire 38 as described above.
[0076] FIGS. 7-10 illustrate one embodiment of the present radially collapsible and expandable thrombus collection device 60 . As described further below, the device 60 is configured to be inserted into a patient's vasculature through an introducer sheath that passes through an opening at a percutaneous access site. When inserted in a collapsed state, the device 60 can be advanced past the thrombus, expanded, and then drawn back to pull the thrombus away from the interior of the vasculature and trap the thrombus within the device 60 . As the expanded device 60 is withdrawn further, it pulls the thrombus proximally through the introducer sheath until it eventually exits the vasculature through the percutaneous opening. This procedure is described further below.
[0077] FIGS. 7 and 8 illustrate the device 60 in a collapsed or contracted state. FIGS. 9 and 10 illustrate the device 60 in an expanded state. An operator may readily expand and contract the device 60 in the radial direction to increase or decrease its external diameter. For example, the external diameter may be decreased to enable the device 60 to pass freely through the introducer sheath. Once deployed in the vasculature, the external diameter may be increased to contact the interior diameter of the vasculature, thereby matching the diameter of a thrombus.
[0078] With reference to FIGS. 7 and 8 , the thrombus collection device 60 comprises an elongate, elastomeric, tubular casing 62 . As shown in the side elevation view of FIG. 7 , the tubular casing 62 extends over a tubular catheter 64 from a distal end 66 of the catheter 64 to a point distal of an opening 68 in the sidewall of the catheter 64 . A space between the catheter 64 and the casing 62 receives a portion of an elongate wire 70 that an operator may manipulate to expand and contract the casing 62 , as described in detail below. While FIG. 7 is not a cross-sectional view, the catheter 64 and the wire 70 are shown beneath the casing 62 for clarity.
[0079] With continued reference to FIG. 7 , a distal end 72 of the wire 70 is disposed at or near a distal end 66 of the catheter 64 . For clarity, a distal portion 74 of the wire 70 that is positioned on the far side of the catheter 64 is shown in hidden lines. In one embodiment, the distal end 72 of the wire 70 may be secured to the catheter 64 . In an alternative embodiment, the distal end 72 of the wire 70 may be freely movable with respect to the catheter 64 and the casing 62 . The distal end 72 of the wire 70 may include a blunt cap (not shown) to reduce the likelihood of the wire 70 puncturing the elastomeric casing 62 .
[0080] Proximal of the wire distal end 72 , the wire 70 forms a helix 76 . The helix 76 includes a plurality of coils 78 that wrap around the catheter 64 beneath the casing 62 . The wire 70 extends past a proximal end 80 of the casing 62 and then through the opening 68 in the catheter 64 . The wire 70 extends through the interior of the catheter 64 proximal of the opening 68 , exiting through a proximal end of the catheter lumen. In an alternative embodiment, the catheter 64 may omit the opening 68 , so that the wire 70 is always disposed externally of the catheter 64 . Further, the wire 70 may have any desired length extending proximally of the casing 62 and/or catheter 64 . As explained in further detail below, an operator may manipulate the proximal end of the wire 70 to force the wire 70 to expand and contract radially in a fashion similar to that described above with respect to the sheath 20 .
[0081] The casing 62 and the wire 70 preferably comprise material properties corresponding to those described above with respect to the casing 30 and the wire 38 of the sheath 20 . Further, the example materials described with respect to the sheath 20 can also be implemented in the present thrombus collection device 60 .
[0082] The catheter 64 preferably comprises a material that is flexible but rigid enough to support the casing 62 and the wire 70 as the device 60 is inserted into a patient's vasculature through an introducer sheath, and also rigid enough to support the casing 62 and the wire 70 as those components radially expand and contract. Further, because the catheter 64 is configured for use internally, the material is preferably biocompatible. Example materials for the catheter 64 include various thermoplastics such as polyimide, fluorinated ethylene propylene (FEP), PEBAX, and other materials having similar properties.
[0083] Again, FIGS. 7 and 8 illustrate the device 60 in a collapsed or contracted state. In this state, the wire 70 includes a relatively straight portion 82 extending between the opening in the catheter 64 , and a helical portion distal of the straight portion 82 . However, when the flexible but incompressible wire 70 is subjected to a compressive force applied proximally of the opening 68 , the wire 70 is forced distally in the space between the casing 62 and the catheter 64 . As the wire 70 moves distally, it forms tighter coils 78 within the helix 76 , with the coils 78 having increasingly larger diameters, as shown in FIGS. 9 and 10 . The elastomeric nature of the casing 62 makes it readily expandable in the radial direction as the wire 70 forces it outward. The expanded casing 62 presents a wide proximal opening 84 to the space between the casing 62 and the catheter 64 . Similarly, when the wire 70 is subjected to a tensile force applied proximally of the opening 68 , the coils 78 within the helix 76 relax as wire 70 is pulled proximally, collapsing the wire 70 and the casing 62 and narrowing the proximal opening 84 . Again, the elastomeric nature of the casing 62 makes it readily contractible in the radial direction as the radial support provided by the wire 70 diminishes.
[0084] In one embodiment, the wire 70 is freely slidable within the space between the casing 62 and the catheter 64 . Thus, as the wire 70 is forced distally, additional wire 70 is forced into the space between the casing 62 and the catheter 64 . The helix 76 slides against the casing 62 and the catheter 64 as it expands radially to enable the casing 62 to expand without forming pleats between adjacent coils 78 . The expanded sheath thus presents a relatively smooth outer diameter for easy passage of the device 60 within the patient's vasculature. However, in alternative embodiments the wire 70 may be secured to the casing 62 at one or more locations, such as at the proximal end 80 of the casing 62 .
[0085] As shown in FIGS. 9 and 10 , the illustrated embodiment of the thrombus collection device 60 expands to form a substantially conical shape, or any other suitable shape, including any tapering shape with a proximal open end and a smaller, closed distal end. To achieve this expanded shape, the casing 62 may, for example, be secured to the catheter 64 at one or more locations along a straight line that traces the outer surface of the catheter 64 . In the illustrated embodiment, this line is along the lower side 86 of the catheter 64 . Because the casing 62 is attached to the catheter 64 , as the wire 70 is forced distally under an applied force the wire 70 and the casing 62 are constrained against expansion on the side 86 of the catheter 64 where the casing 62 is attached, causing the casing 62 to assume a generally conical or elongate conical shape as it expands. The conical expanded shape achieves advantages for thrombus collection, as described in further detail below.
[0086] FIGS. 11-15 illustrate one method of using the thrombus collection device 60 of FIGS. 7-10 to perform a thrombectomy. As shown in FIG. 11 , the thrombus collection device 60 may be combined with the sheath 20 of FIGS. 1-6 to form a system 88 for performing a thrombectomy. However, the present thrombus collection device 60 may be used with any introducer sheath. Thus, the present sheath 20 and thrombus collection device 60 are each usable separately, or in combination.
[0087] With reference to FIG. 11 , a process for extracting a thrombus begins with the operator emplacing the sheath 20 as described above with respect to FIG. 6 . The operator can then expand the sheath 20 by applying a distally directed force to the sheath wire 38 . With the sheath 20 expanded, the operator introduces the thrombus collection device 60 by passing it through the expanded sheath 20 and into the patient's vasculature 22 , as shown in FIG. 11 . To aid introduction, the operator would typically introduce the thrombus collection device 60 in its collapsed state ( FIGS. 7 and 8 ). FIG. 11 , however, illustrates the device wire 70 and the device casing 62 in their expanded states for clarity. Once the device 60 has been introduced into the vasculature 22 , the operator may collapse the sheath 20 by applying a proximally directed force to its wire 38 . In the collapsed state, the sheath 20 advantageously promotes hemostasis at the percutaneous access site 26 by allowing the percutaneous puncture 24 to reduce in size. The collapsed sheath 20 , however, still provides an adequate inside diameter to enable the thrombus collection device 60 to be manipulated within the vasculature 22 . The step of collapsing the sheath 20 is optional.
[0088] With reference to FIG. 12 , the operator advances the device 60 through the patient's vasculature 22 toward the location of the thrombus 90 . The operator may advance the device 60 by applying a distally directed force to the portion of the catheter 64 that protrudes from the percutaneous access site 26 . The operator may use a guide wire (not shown) and/or imaging, such as ultrasound, to assist in guiding the device 60 through the vasculature 22 to the thrombus 90 .
[0089] When the thrombus collection device 60 reaches the thrombus 90 , as shown in FIG. 13 , the operator continues applying distally directed force to push the distal end 66 of the device 60 through the thrombus 90 . The present thrombus collection device 60 is configured to collect acute thrombi, which typically have a gelatin-like consistency. The operator may thus typically pass the device 60 through the thrombus 90 without substantial difficulty. The moderate rigidity of the catheter 64 and the low profile of the device 60 aid in penetrating the thrombus 90 .
[0090] The operator continues advancing the device 60 through the thrombus 90 until the device casing 62 has completely passed through the thrombus 90 . The operator then expands the device wire 70 and the device casing 62 as shown in FIG. 14 . The operator expands the device wire 70 and the device casing 62 by applying a distally directed force to the device wire 70 while holding the catheter 64 stationary. The operator may expand the device wire 70 and the device casing 62 until achieving wall-to-wall apposition with the interior diameter 56 of the vasculature. The operator may use imaging and/or tactile feedback to determine when the device casing 62 is expanded to the desired amount.
[0091] With the device casing 62 expanded and positioned distally of the thrombus 90 , the operator draws the device 60 back through the vasculature 22 by applying a proximally directed force to the catheter 64 while holding the device wire 70 stationary with respect to the catheter to maintain the device casing 62 in its expanded state. As the expanded device 60 is pulled proximally, the proximal opening 84 of the device casing 62 collects the thrombus 90 and traps it within the space between the device casing 62 and the catheter 64 , as shown in FIG. 15 . The operator continues to pull back on the catheter 64 until the thrombus collection device 60 reaches the distal end 42 of the sheath 20 , as shown in FIG. 11 . Again, the operator may use imaging to determine the location of the thrombus collection device 60 . As illustrated, in FIGS. 12-15 , the operator may advantageously advance the device 60 through the thrombus 90 such that the line 86 along which the device casing 62 is attached to the catheter 64 faces the interior wall 56 of the vasculature 22 . Thus, when the conical device casing 62 is expanded, its proximal opening 84 is positioned to completely engulf the thrombus 90 when pulled back.
[0092] When the thrombus collection device 60 reaches the distal end 42 of the sheath 20 , as shown in FIG. 11 , the operator draws the device 60 through the sheath 20 , together with the collected thrombus 90 , until the device 60 and the thrombus 90 are completely extracted from the patient. To aid in extraction, the operator would typically expand the sheath 20 prior to withdrawing the device 60 so that the sheath 20 may better accommodate the expanded device 60 . The sheath 20 may advantageously be expanded over a wide range, so that it can for example be expanded to contact the interior diameter 56 of the vasculature 22 , and be expanded even farther to radially expand the vasculature 22 . This increased expansion is advantageous for withdrawing the thrombus collection device 60 , as the thrombus collection device 60 may sometimes be expanded during withdrawal to a diameter that is substantially equal to the interior diameter of the vasculature 22 . Optionally, the operator can rely upon the natural expandability of the sheath 20 , rather than or in addition to manual expansion of the sheath, to expand the sheath 20 in response to the introduction of a large-diameter object (e.g. the device 60 containing a relatively large portion of thrombus) into the sheath lumen. Upon withdrawing the thrombus collection device 60 , the operator may thereafter collapse the sheath 20 and also withdraw it from the percutaneous access site 26 . Just before or during withdrawal of the device 60 , the operator can pull the device wire 70 proximally so that the wire 70 serves as a clamp or drawstring that holds the collected thrombus in the casing 62 or wire coils more securely during withdrawal.
[0093] In an alternative embodiment of the sheath 20 ′, the sheath wire 38 ′ may not be coiled around the inner layer 32 ′ when the sheath 20 ′ is in the collapsed state. For example, FIG. 16 shows an alternative sheath 20 ′ in which the sheath wire 38 ′ extends substantially straight from the opening 50 ′ to the distal end 42 ′ of the sheath casing 30 ′. Similarly, in an alternative embodiment of the thrombus collection device 60 ′, the device wire 70 ′ may not be coiled around the catheter 64 ′ when the device casing 62 ′ is in the collapsed state. For example, FIG. 17 shows an alternative thrombus collection device 60 ′ in which the device wire 70 ′ extends substantially straight along the catheter 64 ′ from the opening 68 ′ to the distal end 66 ′ of the catheter 64 ′. In both embodiments of FIGS. 16 and 17 , the wire 38 ′, 70 ′ coils around the inner layer 32 ′/catheter 64 ′ in response to a distally directed force applied to the wire 38 ′, 70 ′, substantially as described above with respect to the foregoing embodiments.
[0094] As illustrated above, the present embodiments of the radially collapsible and expandable sheath 20 advantageously provide an introducer sheath that can be adjusted to accommodate intravascular devices of various sizes. The sheath 20 is simple in construction, including only two pieces (the casing 30 and the wire 38 ) in certain embodiments. The sheath 20 is easily adjustable in radial dimension through the application of pushing or pulling force to the wire 38 . The sheath 20 can expand radially on its own in response to movement of a large object into the sheath, such as a large intravascular device or a device carrying a relatively large amount of thrombus. In the latter case, this property of the sheath facilitates removal of large thrombi without need for macerating the thrombi or treating them with a thrombolytic agent before moving them through the sheath. The sheath 20 can be expanded within the vasculature to radially expand the vasculature. When collapsed, the portion of the sheath 20 extending through the percutaneous access opening promotes hemostasis by allowing the opening to partially or completely collapse.
[0095] As also illustrated above, the present embodiments of the radially collapsible and expandable thrombus collection device 60 advantageously provide a collection device that can be collapsed to a low profile for easy introduction to the vasculature through a sheath, and easy penetration of the thrombus. When the collapsed device 60 is advanced past the thrombus, it can be expanded to match the interior diameter of the vasculature and pulled back to entrain the thrombus. It is optional to macerate the thrombus or to soften it with a thrombolytic prior to extraction. The proximal opening of the casing, supported by the wire, simply pulls the thrombus away from the vasculature wall and traps it within the casing. This embodiment is particularly useful for removing thrombi that repeatedly form in arterio-venous fistulas (AVF) of hemodialysis patients. The thrombus collection device 60 enables removal of the thrombi without the need for repeated surgical cut downs. Several devices 60 can be provided in a package or kit for use within a single procedure, e.g. when thrombus is to be removed in several stages each calling for a separate device 60 .
[0096] As also illustrated above, the present embodiments of the radially collapsible and expandable sheath 20 can be combined with the present embodiments of the radially collapsible and expandable thrombus collection device 60 to form a system 88 ( FIG. 11 ) for performing a thrombectomy. The system 88 achieves the combined advantages of each component of the system 88 . Those of ordinary skill in the art will appreciate, however, that both the sheath 20 and the thrombus collection device 60 are usable separately.
[0097] FIG. 18 illustrates another embodiment of the present introducer sheaths. The sheath 100 is tubular, and includes a medial neck portion 102 . At a distal end, the neck portion 102 flares outwardly to a wider bell portion 104 . The distal end 106 of the bell portion 104 is open.
[0098] The neck portion 102 and the bell portion 104 may comprise a compliant material. As used herein, the term compliant should be understood to include at least the following properties: flexibility, elasticity, and collapsibility/expandability. Further, because the sheath 100 is configured for use internally, the material is preferably biocompatible. Example materials for the sheath 100 include silicone film, polyisoprene, TECOTHANE®, PELLETHANE®, and other materials having similar properties. The compliant sheath material is advantageously kink resistant and capable of folding upon itself.
[0099] In one embodiment, the sheath 100 comprises HT-310 synthetic polyisoprene having a thickness of approximately 3-4.5 mils. A length of the bell portion 104 is approximately 26 mm, as measured from the distal end 106 to the transition point 108 between the bell portion 104 and the flared portion 110 . A diameter of the bell portion 104 is approximately 10 mm. A length of the neck portion 102 is approximately 34 mm, as measured from the proximal end 112 to the transition point 114 between the neck portion 102 and the flared portion 110 . A diameter of the neck portion 102 is approximately 7 mm. A length of the flared portion 110 is approximately 10 mm. The foregoing material and dimensions are merely one example, and are not limiting.
[0100] The bell portion 104 of the sheath 100 includes a wire 116 that is encased within the compliant material. Unlike the sheath 20 described above and illustrated in FIGS. 1-6 , the wire 116 is not movable relative to the compliant sheath material. The sheath 100 may, for example, be made by overmolding the compliant sheath material over the wire 116 . The resulting structure keeps the wire 116 in the desired position along the length of the bell portion 104 .
[0101] The wire 116 extends around the circumference of the bell portion 104 along a path that repeatedly doubles back and forth in the direction of the longitudinal axis A of the sheath 100 . As measured in the direction of the longitudinal axis A, the wire 116 extends over approximately half the length of the bell portion 104 from the distal end 106 thereof to approximately the center thereof. As illustrated, however, a narrow band 118 of the bell portion 104 extends beyond the wire 116 at the distal end 106 . A length of this band 118 , as measured in the direction of the longitudinal axis A, may be approximately 1 mm in one embodiment.
[0102] The wire 116 supports the compliant material, maintaining the bell portion 104 in its expanded shape when the sheath 100 is unstressed. The wire 116 comprises a material that is flexible but incompressible. Further, because the wire 116 is configured for use internally, the material is preferably biocompatible. Example materials for the wire 116 include nickel-titanium (NiTi) alloys, stainless steel, polyether ether ketone (PEEK) and other materials having similar properties.
[0103] At a proximal end 120 , the sheath 100 includes a flush port 122 . The flush port 122 includes a tubular portion 124 that is coaxial with the neck portion 102 and the bell portion 104 . Together, the tubular portion 124 , the neck portion 102 and the bell portion 104 define an interior lumen, or sheath lumen (not shown). A port 126 extends radially from the tubular portion 124 . The port 126 defines a port lumen (not shown) that is in fluid communication with the sheath lumen. The port 126 is conically shaped, tapering down to a smaller diameter with increasing distance from the tubular portion 124 . A medial portion of the port 126 includes an annular bulge 128 where the exterior diameter of the port 126 is increased. The port 126 is configured to receive standard medical tubing 130 in a liquid tight friction fit with the tubing 130 extending around the outside of the bulge 128 . An end of the tubing 130 spaced from the port 126 includes a connector 132 . In the illustrated embodiment, the illustrated connector 132 is a female Luer connector 132 . A conical distal end 134 of the connector 132 is received within the tubing 130 in a liquid tight friction fit. The connector 132 includes a stopcock 136 that enables flow through the connector 132 to be selectively blocked. The flush port 122 enables fluid to be injected and/or aspirated from the sheath lumen. For example, a syringe (not shown) may be connected to the connector 132 , and fluid may be injected or aspirated by depressing or drawing back on the syringe plunger.
[0104] The introducer sheath 100 of FIG. 18 is configured for passage into a patient's vasculature (e.g. in a vein or artery, an arterio-venous fistula (AVF) or arterio-venous graft (AVG), or alternatively in a non-vascular location such as the peritoneal cavity or other bodily cavities or hollow anatomical structures) through an opening at a percutaneous access site. Once deployed, the sheath 100 can be used as a conduit for introducing one or more intravascular devices into the patient's vasculature. For example, and as discussed further below, in one embodiment the sheath 100 can be used to introduce a thrombectomy device. FIG. 18 illustrates the introducer sheath 100 in an unstressed, or expanded, configuration. The compliant portions of the introducer sheath 100 are configured to be radially compressed for ease of introduction into the vasculature, as described below. Once deployed within the vasculature, a hemostasis valve 138 at the proximal end of the sheath 100 ( FIG. 20 ) resists outflow of bodily fluids through the sheath 100 . The hemostasis valve 138 is shaped substantially as a disk, and is located within the tubular portion 124 at the proximal end 120 thereof. The valve 138 may, for example, comprise a foam material. The valve 138 forms a seal around the exterior of a tubular dilator 140 , which is described below.
[0105] FIGS. 19 and 20 illustrate one embodiment of a deployment apparatus 142 for the introducer sheath 100 of FIG. 18 . With reference to the cross-sectional view of FIG. 20 , the deployment apparatus 142 includes a tubular dilator 140 , which may also be referred to as a hypotube 140 . The dilator 140 is a rigid or semi-rigid component configured to guide the deployment apparatus 142 through a skin puncture and through the vasculature, as described in further detail below. The dilator 140 includes a proximal handle 144 , a conically shaped distal tip 146 , and defines a lumen 148 that extends between the proximal and distal ends. The handle 144 is shaped as a round knob. The lumen 148 extends through the handle 144 and through the distal tip 146 . The lumen is configured to receive a guide wire (not shown) to facilitate introduction of the dilator 140 into a patient, as described in detail below.
[0106] With continued reference to FIG. 20 , the introducer sheath 100 of FIG. 18 is disposed coaxially about the outside of the dilator 140 , and an outer sheath 150 is disposed coaxially about the outside of the introducer sheath 100 . The outer sheath 150 has an inner diameter that is approximately equal to an outer diameter of the neck portion 102 of the introducer sheath 100 , but less than the outer diameter of the bell portion 104 of the introducer sheath 100 . The outer sheath 150 thus radially compresses the bell portion 104 , which facilitates introduction of the sheath 100 into the patient. In certain embodiments, the outer sheath 150 comprises a non-elastic material so that the radially compressed bell portion 104 does not induce expansion of the outer sheath 150 .
[0107] The outer sheath 150 , however, is a tearaway sheath. Thus, it comprises a material that can be torn by hand. Example materials include polytetrafluoroethylene (PTFE) and materials having similar properties. The outer sheath 150 includes a proximal handle 152 that extends radially away from the outer sheath 150 at a location just distal of the tubular portion 124 of the introducer sheath 100 . As discussed further below, the operator may remove the outer sheath 150 by grasping the handle 152 and pulling it proximally while holding the introducer sheath 100 and the dilator 140 steady. The outer sheath 150 material tears away from the deployment apparatus 142 as it is withdrawn from the percutaneous access site. Once the outer sheath 150 is removed, the bell portion 104 of the introducer sheath 100 expands to its unstressed condition, subject to any stresses applied by the patient's vasculature.
[0108] FIGS. 21-24 illustrate one embodiment of a method for deploying the introducer sheath 100 of FIG. 18 in a patient's vasculature 154 at a percutaneous access site 156 using the deployment apparatus 142 of FIGS. 19 and 20 . The access site 156 may be prepared by puncturing the skin 158 , any underlying tissue 160 , and the vasculature 154 with a needle 162 , as shown in FIG. 21 . The operator then introduces a guide wire 164 through the lumen of the needle 162 , and withdraws the needle 162 .
[0109] With reference to FIG. 22 , the operator introduces the deployment apparatus 142 into the vasculature 154 through the puncture site 156 using the guide wire 164 . The operator threads the guide wire 164 into the dilator lumen 148 ( FIG. 20 ) from the distal end 146 and advances the deployment apparatus 142 through the puncture site 156 . In some embodiments the dilator 140 is a rigid component that provides sufficient column strength to facilitate tissue puncturing and/or penetration. However, in alternative embodiments the dilator 140 includes sufficient flexibility to facilitate navigating tortuous vasculature 154 . The conically shaped distal tip 146 of the dilator 140 facilitates passage of the deployment apparatus 142 through the patient's tissue 160 ( FIG. 21 ) and into the vasculature 154 .
[0110] With reference to FIGS. 22 and 23 , after penetrating the vasculature 154 the deployment apparatus 142 is advanced through the vasculature 154 until the handle portion 152 of the outer sheath 150 approaches the puncture site 156 . In this position, the introducer sheath 100 is located such that the bell portion 104 is located entirely within the vasculature 154 and the neck portion 102 traverses the puncture site 156 . The hemostasis valve 138 ( FIG. 20 ) within the introducer sheath 100 resists outflow of blood through the annular space defined by the interior of the sheath 100 and the exterior of the dilator 140 . The dilator 140 may also include a hemostasis valve (not shown) to resist outflow of blood through the dilator lumen 148 .
[0111] With reference to FIG. 23 , the operator next removes the outer sheath 150 from the deployment apparatus 142 . As indicated above, the outer sheath 150 is a tearaway sheath. Thus, to remove the outer sheath 150 , the operator grasps the handle 152 and pulls it proximally while holding the introducer sheath 100 and the dilator 140 steady. The operator may, for example, grasp the outer sheath handle 152 with one hand and the dilator handle 144 with the other hand. The outer sheath 150 tears away from the remainder of the deployment apparatus 142 and pulls through the puncture site 156 .
[0112] With reference to FIGS. 23 and 24 , the operator draws the entire outer sheath 150 out of the body through the puncture site 156 . Upon removal of the outer sheath 150 , the compressive force applied to the introducer sheath 100 by the outer sheath 150 is no longer present. The bell portion 104 of the introducer sheath 100 thus expands as the stored energy in the wire 116 is released. FIG. 24 illustrates the introducer sheath 100 in its expanded state within the vasculature 154 . Depending upon the relative dimensions of the introducer sheath 100 and the vasculature 154 , the vasculature 154 may constrain the expansion of the introducer sheath 100 somewhat so that it does not achieve the fully relaxed state that it would outside the body. Skin 158 and underlying tissue 160 further constrain expansion of the neck portion 102 where it traverses the puncture site 156 .
[0113] With reference to FIGS. 23 and 24 , after removing the outer sheath 150 the operator next removes the dilator 140 . To remove the dilator 140 , the operator draws back on the proximal handle 144 . During withdrawal, the operator may optionally apply digital pressure at the puncture site 156 in order to prevent the introducer sheath 100 from being withdrawn together with the dilator 140 due to friction between those two components where they are squeezed by the elastic skin 158 at the puncture site 156 . With the dilator 140 completely removed, the introducer sheath 100 is disposed within the vasculature 154 through the puncture site 156 as shown in FIG. 24 . The tubular portion 124 is disposed exteriorly of the body, the bell portion 104 is disposed within the vasculature 154 , and the neck portion 102 traverses the skin 158 and tissue 160 therebetween. Advantageously, the compliant nature of the neck portion 102 promotes hemostasis at the puncture site 156 by allowing the elastic skin 158 to collapse around the puncture. The compliant neck 102 further speeds hemostasis at the end of a procedure, because the skin 158 and underlying tissue 160 do not remain stretched for an extended period. The hemostasis valve 138 within the proximal end 120 of the introducer sheath 100 ( FIG. 20 ) further promotes hemostasis at the puncture site 156 . When the dilator 140 is withdrawn, the hemostasis valve 138 may close to seal the opening formerly occupied by the dilator 140 . The valve 138 may reopen as additional apparatus is introduced into the vasculature 154 through the sheath 100 . However, the valve 138 preferably forms a seal around any such apparatus.
[0114] The introducer sheath 100 described above may advantageously be used to introduce a wide variety of instruments into a patient's vasculature 154 . For example, the introducer sheath 100 may be used to introduce a thrombus collection device. Various examples of thrombus collection procedures using the present embodiments are described below.
[0115] FIGS. 25 and 26 illustrate an aspiration catheter 166 , which is another embodiment of the present thrombus collection devices. With reference to FIG. 25 , the catheter 166 includes an elongate body 168 having a balloon 170 at its distal end 172 . The catheter body 168 comprises a flexible material that is configured for navigating tortuous vasculature. However, the catheter body 168 material includes sufficient rigidity to facilitate guiding the catheter 166 through the vasculature from the proximal end 174 . Example materials for the catheter body 168 include polyether block amide (PEBAX®) and materials having similar properties.
[0116] FIG. 26 illustrates a cross-sectional view of the catheter body 168 . The body 168 defines two radially spaced lumens 176 , 178 that are not in fluid communication with one another. The first lumen 176 is an aspiration lumen 176 that extends from an aspiration connector 180 ( FIG. 25 ) at the proximal end 174 of the catheter 166 to a plurality of aspiration openings 182 toward the distal end 172 of the catheter 166 . The second lumen 178 is an inflation lumen 178 that extends from an inflation connector 184 at the proximal end 174 of the catheter 166 to the balloon 170 toward the distal end 172 of the catheter 166 . The aspiration lumen 176 has a larger diameter than the inflation lumen 178 , and is configured for passage of thrombus, as described below. In one embodiment, the catheter body 168 may have a diameter of 6 Fr, while the aspiration lumen 176 may have a diameter of 0.055″.
[0117] In certain embodiments, the aspiration lumen 176 may further extend to the distal end 172 , which is open but sealed by a valve (not shown). The valve enables a guide wire (not shown) to pass to facilitate introduction of the catheter 166 into the vasculature. However, upon withdrawal of the guide wire the valve seals to resist flow into or out of the distal end 172 of the aspiration lumen 176 .
[0118] With reference to FIG. 25 , the aspiration connector 180 and the inflation connector 184 extend proximally from a Y-shaped body 186 . The body 186 includes a main conduit 188 that extends inline with the catheter body 168 . The aspiration connector 180 extends proximally from the main conduit 188 , inline therewith. The body 186 further includes a branch conduit 190 that extends at an angle from the body 186 . The inflation connector 184 extends proximally from the branch conduit 190 , inline therewith. In the illustrated embodiment, both connectors 180 , 184 comprise a female Luer connector including an external thread 192 . In alternative embodiments different types of connectors could be substituted. In certain embodiments, either or both of the connectors 180 , 184 may include a stopcock (not shown) for selectively halting liquid flow through the connector(s) 180 , 184 .
[0119] The Y-shaped body 186 and the connectors 180 , 184 may be formed as a single piece or as multiple pieces. These portions are preferably formed from a rigid medical grade plastic. For example, these portions may comprise polycarbonate, acrylic, polypropylene, styrene, or any other suitable plastic material.
[0120] With continued reference to FIG. 25 , and as indicated above, the aspiration catheter 166 includes a plurality of aspiration openings 182 toward the distal end 172 . Three openings are shown, but other embodiments may include any number of openings 182 , including only a single opening 182 . The aspiration openings 182 are in fluid communication with the aspiration connector 180 through the aspiration lumen 176 . During a thrombus collection procedure, a syringe (not shown) may be connected to the aspiration connector 180 . Drawing back upon a plunger of the syringe creates suction at the aspiration openings 182 . The suction can be used to draw pieces of the thrombus into the aspiration lumen 176 for removal from the vasculature. This process is described more fully below.
[0121] The aspiration catheter 166 further includes a balloon 170 toward the distal end 172 . The balloon 170 is shown in a partially inflated state for illustration. The balloon 170 is sealed at its proximal end 194 and distal end 196 to the catheter body 168 . An inflation port (not shown) passes through the wall of the catheter body 168 within the balloon 170 . The interior of the balloon 170 is in fluid communication with the inflation lumen 178 through the inflation port. During a thrombus collection procedure, a syringe (not shown) may be connected to the inflation connector 184 . The balloon 170 may be inflated by depressing the syringe plunger to force a fluid through the inflation lumen 178 and into the balloon 170 . The balloon 170 may be deflated by drawing the syringe plunger back to evacuate the fluid from the balloon 170 . For intravascular procedures, the inflation fluid is preferably a non-toxic liquid, such as saline. Thus, as used herein the terms inflate and deflate are to be construed broadly enough to include using a liquid as the inflation agent.
[0122] As described above, the aspiration catheter 166 shown in FIGS. 25 and 26 is configured for percutaneously removing a thrombus from a patient's vasculature. FIGS. 27-35 illustrate one example of such a procedure. In FIGS. 27-34 , each drawing sheet illustrates the proximal portions (odd numbered figures) of the introducer sheath 100 and the aspiration catheter 166 and the distal portions (even numbered figures) as they appear during the same step of the procedure. In other words, FIGS. 27 and 28 illustrate different portions of the apparatus during the same step of the procedure, FIGS. 29 and 30 illustrate different portions of the apparatus during a subsequent step of the procedure, etc.
[0123] With reference to FIGS. 27 and 28 , the aspiration catheter 166 is introduced into the vasculature 154 through the introducer sheath 100 described above with respect to FIGS. 18-24 . The introducer sheath 100 may be deployed according to the method described above with respect to FIGS. 21-24 . The aspiration catheter 166 is then advanced distally through the sheath 100 , the vasculature 154 , and the thrombus 198 until the balloon 170 is disposed on the far side of the thrombus 198 ( FIG. 28 ). A guide wire 164 extending through the aspiration lumen 176 may be used to advance the catheter 166 . As shown, the catheter 166 is advanced with the balloon 170 in the deflated state for ease of passage through the sheath 100 , the vasculature 154 and the thrombus 198 . The conically shaped distal tip 172 further facilitates passage of the catheter 166 , especially through the constricted portion of the sheath 100 that traverses the puncture site, and through the thrombus 198 .
[0124] With reference to FIGS. 29 and 30 , when the catheter 166 has advanced sufficiently that the balloon 170 is disposed on the far side of the thrombus 198 , the operator connects a syringe 200 ( FIG. 29 ) filled with inflation liquid to the inflation connector 184 . As shown, a Luer stopcock 202 may be connected between the syringe 200 and the inflation connector 184 . The operator depresses the syringe plunger 204 to force the inflation liquid into the balloon 170 through the inflation lumen 178 . The operator inflates the balloon 170 until it presses against the interior walls of the vasculature 154 on the far side of the thrombus 198 ( FIG. 30 ). If the stopcock 202 is not provided, the operator maintains the syringe 200 connected to the inflation connector 184 in order to maintain the inflation pressure within the balloon 170 . However, if the stopcock 202 is provided, the operator moves the stopcock 202 to a position to prevent liquid flow through the inflation connector 184 . The operator may then disconnect the syringe 200 from the stopcock 202 , which may make it easier for the operator to perform subsequent steps of the procedure.
[0125] With reference to FIGS. 31 and 32 , the operator removes the thrombus 198 from the vasculature 154 by using a combination of suction through the aspiration openings 182 , and proximal movement of the inflated balloon 170 across the thrombus 198 . These actions may occur simultaneously, or in succession, or alternatingly. The following discussion describes a method for applying suction simultaneously while drawing the inflated balloon 170 across the thrombus 198 . This illustrated method is only one of many possibilities for removing the thrombus 198 , and is not intended to be limiting.
[0126] With reference to FIG. 31 , the operator connects a Luer stopcock 202 to the aspiration connector 180 and an empty syringe 206 to the stopcock 202 . If a guide wire 164 was used to advance the catheter 166 , it is removed prior to connection of the syringe 206 . The syringe 206 is configured so that the plunger 208 can be drawn back to create a vacuum within the barrel 210 and the plunger 208 locked to maintain the vacuum. One such syringe is sold under the trade name VACLOK®. To generate suction, the operator draws back on the syringe plunger 208 with the stopcock 202 in the closed position and then locks the plunger 208 . The operator then draws the catheter 166 out of the vasculature 154 while simultaneously moving the stopcock 202 to the open position. Moving the stopcock 202 to the open position exposes the vacuum in the syringe barrel 210 to the aspiration lumen 178 , generating suction that pulls pieces of the thrombus 198 into the aspiration lumen 176 through the aspiration openings 182 . The aspiration openings 182 thus advantageously assist in collecting the thrombus 198 both by tearing away pieces of thrombus 198 from the larger whole, and by vacuuming up any loose pieces of thrombus 198 . Some of these pieces of thrombus 198 may be sucked into the syringe 206 , as shown in FIG. 31 .
[0127] Because the operator draws the catheter 166 out of the vasculature 154 simultaneously while generating suction at the aspiration openings 182 , the aspiration openings 182 are more likely to be exposed to all portions of the thrombus 198 as the openings 182 are drawn across the thrombus 198 , as shown in FIG. 32 . The suction is thus more likely to remove more of the thrombus 198 than if the catheter 166 remains stationary while the vacuum is applied. In certain embodiments, the aspiration openings 182 may be located within the thrombus 198 at the point in the procedure where the operator opens the stopcock 202 . In alternative embodiments, some or all of the openings 182 may be disposed proximally and/or distally of the thrombus 198 at this point in the procedure.
[0128] In addition to the vacuum action, pulling back on the aspiration catheter 166 pulls the balloon 170 against the distal side of the thrombus 198 , as shown in FIG. 32 . The balloon 170 , which fills the circumference of the vasculature 154 , pulls the thrombus 198 away from the vasculature 154 . Portions of the thrombus 198 that are not sucked into the aspiration lumen 176 are drawn into the sheath 100 by the balloon 170 .
[0129] With continued reference to FIG. 32 , the operator continues to pull back on the aspiration catheter 166 until all or substantially all of the thrombus 198 has been pulled into the sheath 100 . The operator then continues to pull back on the aspiration catheter 166 in order to force the thrombus 198 out of the vasculature 154 through the sheath 100 . The balloon 170 is withdrawn through the percutaneous access site and into the portion of the sheath 100 that is disposed outside the body. The compliant material of the sheath 100 is advantageously able to expand as the inflated balloon 170 passes so that the balloon 170 can push the pieces of thrombus 198 out of the body. The compliant sheath 100 then collapses as the elastic skin at the puncture site constricts, advantageously facilitating hemostasis. With reference to FIG. 33 , the thrombus 198 and balloon 170 are eventually pulled through the proximal end 120 of the introducer sheath 100 . The introducer sheath 100 may include a hinged proximal door 212 at the proximal end 120 that facilitates withdrawal of the inflated balloon 170 .
[0130] After the thrombus 198 has been removed from the vasculature 154 the introducer sheath 100 remains in the vasculature 154 through the percutaneous access site. The sheath 100 advantageously maintains a path into the vasculature 154 so that a guide wire 164 ( FIG. 35 ) may be reinserted into the vasculature 154 as shown. It may be advantageous to reinsert a guide wire 164 so that the location of the removed thrombus 198 can be re-accessed. Repeat access may be desired so that the thrombus 198 removal procedure may be repeated or so that a stent may be placed, for example. After the guide wire 164 is reinserted, the introducer sheath 100 may be removed if desired, as shown in FIG. 35 .
[0131] The aspiration catheter 166 illustrated in FIG. 25 includes three aspiration openings 182 . The present aspiration catheters may include any number of aspiration openings 182 . However, it has been found that three aspiration openings 182 achieve advantageous thrombus removal results. Further, providing more than one aspiration opening 182 advantageously maintains suction in the event that a first aspiration opening 182 becomes clogged. In the illustrated embodiments, each of the aspiration openings 182 on the catheter 166 has substantially the same diameter. However, in alternative embodiments the aspiration openings 182 could have varying diameters. For example, a diameter of the openings 182 may increase with increasing distance from the source of suction (the syringe 206 at the aspiration connector 180 ) in order to combat head losses across the openings 182 .
[0132] FIG. 36 illustrates another embodiment of an aspiration catheter 214 . The catheter 214 of FIG. 36 is similar to the catheter 166 of FIG. 25 , except that it includes only two aspiration openings 182 , and the distal balloon 216 has a different shape. The balloon 216 of FIG. 36 is shaped substantially as an arrowhead in profile. It includes a cone-shaped distal surface 218 and a proximal surface 220 shaped as an inverted cone. The inverted cone shape urges fluid to flow toward the centerline of the catheter 214 as the balloon 216 is pulled proximally. The flow direction carries thrombus particles toward the aspiration openings 182 , where they are more likely to be sucked into the aspiration lumen 176 . The balloon 216 thus increases the efficiency with which thrombus particles can be collected in the aspiration lumen 176 .
[0133] As shown in FIGS. 27-35 , the introducer sheath 100 of FIG. 18 may be used to introduce the aspiration catheter 166 of FIG. 25 into a patient's vasculature 154 . However, both the introducer sheath 100 and the aspiration catheter 166 can be used in a wide variety of procedures other than a percutaneous thrombus collection procedure. For example, the introducer sheath 100 and the aspiration catheter 166 can be used in non-vascular locations such as the peritoneal cavity or other bodily cavities or hollow anatomical structures.
[0134] Further, both the introducer sheath 100 and the aspiration catheter 166 can be used with a wide variety of other apparatus. It should be understood that any of the apparatus described herein can be used separately, and/or in combination with any of the other apparatus described herein, and/or in combination with other apparatus not described herein. Several of these combinations are described below. It should be further understood that wherever the aspiration catheter 166 of FIG. 25 is described, the aspiration catheter 214 of FIG. 36 may be substituted therefore, wherever the sheath 100 of FIG. 18 is described, the sheath 20 of FIGS. 1-6 or the sheath 20 ′ of FIG. 16 may be substituted therefore, and wherever the thrombus collection device 60 of FIGS. 7-10 is described, the thrombus collection device 60 ′ of FIG. 17 may be substituted therefore.
[0135] With reference to FIG. 37 , the introducer sheath 100 of FIG. 18 can be used to introduce a standard Fogarty balloon catheter 222 into the vasculature 154 . Fogarty balloon catheters are well known, and will not be described in detail herein. The procedure for introducing the sheath 100 is as described above with respect to FIGS. 21-24 , and the procedure for introducing the Fogarty catheter 222 is similar to the procedure described above with respect to FIGS. 27 and 28 .
[0136] With reference to FIG. 38 , the introducer sheath 100 of FIG. 18 can also be used to introduce the thrombus collection device 60 of FIGS. 7-10 into the vasculature 154 . The procedure for introducing the sheath 100 is as described above with respect to FIGS. 21-24 . The procedure for introducing the thrombus collection device 60 is described above with respect to FIGS. 11-15 , except that the sheath 100 of FIG. 18 is substituted for the sheath 20 of FIGS. 1-6 .
[0137] With reference to FIG. 39 , the aspiration catheter 166 of FIG. 25 can be introduced into the vasculature 154 through a standard balloon catheter introducer sheath 224 . Balloon catheter introducer sheaths are well known, and will not be described in detail herein. The procedure for introducing the sheath 224 is similar to the procedure described above with respect to FIGS. 21-24 . The procedure for introducing the aspiration catheter 166 is described above with respect to FIGS. 27 and 28 , except that the balloon catheter introducer sheath 224 is substituted for the sheath 100 of FIG. 18 .
[0138] While not illustrated herein, the introducer sheath 100 of FIG. 18 and the aspiration catheter 166 of FIG. 25 can also be used with other apparatus. For example, the sheath 20 of FIGS. 1-6 can be used to introduce the aspiration catheter 166 of FIG. 25 or the Fogarty balloon catheter 222 of FIG. 37 . Further, the standard balloon catheter introducer sheath 224 of FIG. 39 can be used to introduce the thrombus collection device 60 of FIGS. 7-10 .
[0139] As illustrated above, the present embodiments of the introducer sheath 100 and the aspiration catheter 166 offer numerous advantages. For example, with reference to the introducer sheath 100 of FIG. 18 , the bell portion 104 expands upon deployment so that it contacts the interior walls of the vasculature 154 proximally of the thrombus 198 ( FIGS. 24 and 28 ). When a balloon 170 is then placed distally of the thrombus 198 and inflated, the thrombus 198 is isolated between the bell portion 104 and the balloon 170 . Since the bell portion 104 is open at its distal end 106 , drawing back the balloon 170 sweeps the thrombus 198 into the open mouth of the bell portion 104 . The removal process thus tends to reduce migration of thrombus 198 , and to collect a greater amount of the thrombus 198 as opposed to procedures not including a sheath having a wide, open distal end.
[0140] The introducer sheath 100 of FIG. 18 is also advantageously compliant. It is thus able to expand to allow the withdrawal of thrombus 198 and an inflated catheter balloon 170 . The sheath 100 thus enables a greater amount of thrombus 198 to be collected as compared to non-compliant sheaths 100 . For example, clot burdens in arterio-venous fistulas (AVF) tend to be large, making them hard to remove percutaneously. The expandable compliant sheath 100 is well suited for removing these types of thrombus 198 . Further, it is advantageous to remove the plug portion of a thrombus 198 . The plug (not shown) is a relatively hard portion of thrombus 198 at the anastomosis where the vein is sewn to the artery. The harder plug tends not to compress as it is withdrawn percutaneously. The expandable compliant sheath 100 is thus well suited for removing the plug. The compliant nature of the sheath 100 facilitates removal of large thrombi 198 and plugs without need for macerating the thrombi and plugs or treating them with a thrombolytic agent before moving them through the sheath 100 .
[0141] The expandable sheath 100 further enables devices of varying sizes to pass through it, so that various devices can be used during a single procedure without having to exchange the sheath 100 for a differently sized one. The compliant sheath 100 is also able to contract to maintain hemostasis at the percutaneous access site 156 after the catheter 166 has been withdrawn. The compliant sheath 100 further speeds hemostasis at the end of a procedure, because the skin and underlying tissue do not remain stretched for an extended period.
[0142] With reference to the aspiration catheter 166 of FIG. 25 , the configuration of the catheter 166 advantageously provides push/pull inflation and aspiration. To inflate the balloon 170 , the operator need only connect a syringe 200 filled with inflation liquid and push the plunger 204 . To provide the suction force for thrombus aspiration, the operator need only connect an empty syringe 206 , draw back and lock the plunger 208 , then release the stopcock 202 while pulling on the catheter 166 . This push/pull inflation and aspiration provides mechanical stability that contributes to lesser incidence of user error.
[0143] Both the introducer sheath 100 and the aspiration catheter 166 are also advantageously compatible with existing apparatus. As illustrated above, the introducer sheath 100 can be used to introduce a standard Fogarty balloon catheter 222 , and the aspiration catheter 166 can be introduced with a standard balloon catheter introducer sheath 224 . The introducer sheath 100 and the aspiration catheter 166 are thus easily adaptable to existing procedures that involve apparatus already familiar to those in the field. | A sheath comprises an elastomeric tube having a self-expanding scaffold coupled to a wall. The scaffold can expand to a diameter larger than the tube diameter to provide an enlarged distal opening. An aspiration catheter has a balloon and an aspiration port so that occlusive material can be removed from a blood vessel by drawing the balloon through the vessel while simultaneously aspirating through the port. | 98,418 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Application Ser. No. 60/494,974, filed Aug. 14, 2003, and incorporated herein by reference.
BACKGROUND
[0002] Individual investors seeking diversification and professional management of their investments have frequently chosen mutual funds as their preferred investment vehicle. Often a small or mid-tier investor would hold a small portfolio of individual securities for speculation or amusement, but would look to mutual funds for long-term growth. Only the wealthiest investors had sufficient assets to build well-diversified portfolios from individual securities or attract the attention of professional money managers.
[0003] For many investors, managed accounts are a superior alternative to mutual funds. Two advantages they offer investors are direct ownership of securities and a tax regime in which only the investor's own portfolio determines the investor's tax liability. However, managed accounts require a large investment that is prohibitive to all but the wealthiest investors.
SUMMARY
[0004] In one embodiment, customizable, index-based stock management methodology is provided. This methodology provides for diversification and risk control of indexing combined with individual customization and active tax management. A system employing the methodology permits individual investors to invoke investment processes that track indexes to gain specified market exposure, control risk, and minimize costs while invoking individual preferences, current holdings, or social concerns.
[0005] Security selection and indexing systems and methods are provided to allow smaller investors to achieve similar performance of a target index in separately managed accounts. These systems and methods (“active indexing”) provide pre-tax performance similar to those of specific benchmark indexes with a subset of securities. Furthermore, active tax management strategies allow for greater post-tax returns. Active indexing provides similar returns to a target index and the tax management strategies only available to separately managed accounts but without the large investment required by traditional managed accounts.
[0006] As an aid to understanding the disclosure herein, the Standard and Poor's 500 Index (S&P 500) is used as an exemplary index in a non-limiting context. Other indexes may be selected as a matter of design choice, such as an investor's preference. For example, an investor may select a health care index, over the S&P 500, in the belief that such an index would be more lucrative than a general market index. The S&P 500 has established categories (“sectors”) within the S&P 500 determined by the Global Industry Classification Standard (“GICS”). If another publicly available index or custom index is used, then a corresponding subdivision of the index into sectors may be made to further distinguish subsections comprising the index. When referring to the S&P 500 exemplary index, individual securities may be referred to as stocks. However, if another index is substituted for the S&P 500, individual securities may be bonds, commodities, futures contracts, or other financial instruments that comprises the selected index.
[0007] In one embodiment, a security selection method is provided to achieve similar pre-tax performance of the target index with a subset of the constituent securities. The method may comprise selecting an index, determining the index's sector weights, selecting a target number of securities for the account, and purchasing the securities.
[0008] An index is selected based on an investor's preference, existing portfolio, and/or other personal or strategic factors. For example, a belief that the general market is a lucrative investment may lead an investor to select the S&P 500. Next, the index's sector weights are determined. Weighting by market capitalization is one method of determining weights. Other weighting methods may be employed to target a particular segment of the market, for example, earnings ratio, yield, debt-to-equity, market share, or other attribute. Weighting of the index is reflected by the weighting of the sectors within the portfolio. For example, if the S&P 500 energy sector has a market capitalization of $200 billion and the health care segment has a market capitalization of $100 billion, the portfolio would be built with a corresponding capitalization having substantially twice the investment in the energy sector stocks as health care sector. Optionally, an adjustment may be employed to exclude securities or sectors based on, for example, an investors existing portfolio or investment strategy. Adjustment factors provide a custom index that may be created from a publicly available index and modified to suit the investor. As a benefit, an investor who views a particular industry segment as detrimental or lucrative to his portfolio may modify the index. As another benefit, investors that have an existing investment in a given sector may not wish to increase their exposure in that sector and the resulting index may then exclude the given sector. Individual securities may be excluded, as discussed below. Once the sectors and sector weights of an index have been determined, and optionally customized, individual securities are selected.
[0009] In another embodiment, methods of selecting securities within a sector is provided. In the embodiment, securities are sorted by market capitalization, from largest to smallest. Categories of securities are then determined based on an investor's preference.
[0010] In another embodiment, a division of securities within sector is determined by buckets. As a further embodiment, buckets are market capitalization tranches.
[0011] In another embodiment, a target number of securities are selected reflective of an investor's objectives. The investor's preference may be governed by cost of trading large versus small blocks of securities, diversification preferences, or other personal or strategic objectives.
[0012] In another embodiment, the number of securities to put into each sector is determined. The number of target securities is preferably larger than the number of sectors in the index. At least one security is put into each sector first, then the number of securities per sector is determined by:
ROUND[(percentage of securities in sector)×(total number of securities desired−number of sectors)]+1.
[0013] In another embodiment, an investor may wish to exclude a selected security. As an option the excluded security is omitted. As another option, the target index is customized to exclude the excluded security. As yet another option, a substitute security replaces the excluded security. And as yet another option, additional investment in other selected securities replaces the excluded security.
[0014] In another embodiment, an exchange traded fund (“ETF”) is added to a portfolio with a number of securities below a threshold number, such as 50. As a benefit, adding an ETF to a small security-count portfolio may reduce its index tracking error.
[0015] In another embodiment, the ETF comprises a reserve, such as 1% of the portfolio, to provide a ready source of liquidity to pay fees and to provide reserve for market fluctuations between the determination of a portfolio to acquire and the actual acquisition cost.
[0016] In another embodiment, a percentage of the portfolio is cash, such as 1% to provide a ready source of liquidity to pay fees and to provide reserve for market fluctuations between the determination of a portfolio and the actual acquisition of the portfolio.
[0017] As markets fluctuate, a need for rebalancing may arise to keep the portfolio aligned with the target index. In one embodiment, rebalancing is applied to a sector, category, or individual security. If a sector misweight is greater than a misweight threshold, such as 2%-absolute the sector is rebalanced. Using cash from tax-loss harvesting, disclosed below, replacement securities are then selected. The largest underweight sector is rebalanced first by purchasing constituent securities. If a sector is missing a security, the missing security is purchased first according to the initial allocation, disclosed above. For example, if the sector has 9 securities, it would then purchase security number 10 from the next category to be populated. If the sector is not missing any securities, additional shares of existing securities are purchased. Securities in the first category, such as the first tranche, may be purchased according to the initial portfolio setup, such as purchasing tranche 1 securities from largest to smallest and tranches 2, 3, or 4 securities from the next closest to the median. As an option, a replacement method may be selected which is dissimilar to the method used to populate the initial portfolio.
[0018] In another embodiment, additional rebalancing occurs repeatedly as needed. Securities at or above the over-weighted threshold are sold and rebalanced but additional rebalancing may be required at the sector level, even though no individual security is overweight. Sector securities are sold to eliminate a sector over-weight.
[0019] In another embodiment, tax-loss harvesting is provided. As a security declines in price, upward price potential may still be present. Simultaneously, the owner may wish to realize the lost value of the security for tax purposes. Current tax laws in countries such as the United States prohibit realizing a loss if the same security is purchased 30 days before or after the sale, known as the “Wash Sale Rule.” By repurchasing a similar security, e.g., purchasing Ford after selling General Motors, or purchasing McDonnell Douglas after selling Boeing, a sector's position is rebalanced back to the target index and a tax loss may be realized.
[0020] In another embodiment, dividend income is invested in ETF until a threshold, for example 1.5% of the portfolio value, is held in the ETF. Once the ETF threshold is met, securities are purchased according to at least one methodology disclosed herein.
[0021] In another embodiment, total portfolio liquidation is provided by selling all securities, ETF, and other non-cash holdings. As an option the account may be closed. In another embodiment, a partial reduction in holdings is executed; as an option, the owner of the account may receive a disbursement of the resulting funds. As a further option, the remaining portfolio is rebalanced.
BRIEF DESCRIPTION OF ILLUSTRATED EMBODIMENTS
[0022] FIG. 1 shows a stock selection and indexing system.
[0023] FIG. 2 . shows one process embodiment for selecting and indexing stocks.
[0024] FIG. 3 , FIG. 4 , FIG. 5A , FIG. 5B , FIG. 5C , FIG. 6 , FIG. 7A , FIG. 7B , FIG. 7C , FIG. 7D , FIG. 7E , FIG. 7F , FIG. 8A , FIG. 8B , FIG. 9A , FIG. 9B , FIG. 10A , FIG. 10B , FIG. 11A and FIG. 11B illustrate an embodiment of processes for selecting and manage securities.
[0025] FIG. 12 illustrates tax savings obtained.
[0026] FIG. 13 illustrates tracking differences.
[0027] FIG. 14 illustrates distribution curves pre-tax.
[0028] FIG. 15 illustrates benefits of stock selection and indexing according to the teachings herein.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0029] FIG. 1 shows a stock selection and indexing system 10 that applies principles of stock indexing while providing customization and tax management capabilities. System 10 is shown in an exemplary architecture that includes a server 12 . Server 12 has stock selection and indexing software 14 , a processor 16 and a database 18 . A remote computer 20 may connect with server 12 through a network 22 (e.g., the Internet) such that a user at computer 20 may initiate and run software 14 . For example, processor 16 responds to requests from network 22 to initiate and run software 14 . Results from software 14 may be stored locally within database 18 or communicated over network 22 to computer 29 , for example.
[0030] Server 12 may also connect with remote databases 24 that provide, for example, information (e.g., price) regarding traded securities on the stock exchange. Databases 24 may connect to server 12 through a network 26 (e.g., the Internet).
[0031] Server 12 may also connect with a management computer 28 , through network 30 (e.g., a local area network), which may be used to update software 14 , for example.
[0032] In an example of operation, system 10 provides selection and indexing of securities in response to user requests at computer 20 . Through separately managed accounts, each such user (investor or client) may utilize system 10 to manage direct ownership of securities, customizing stock portfolios to individual needs and preferences while managing taxes. As described in more detail below, tax-management strategies may be employed to shelter gains and harvest losses to increase after-tax returns.
[0033] Indexing employed by system 10 may serve to maximize market exposure while minimizing portfolio risk, to match performance of a particular index by investing in all, or a subset of, securities within the targeted index. System 10 may therefore build portfolios that provide a pre-tax return similar to a selected benchmark that is consistent with requested customization and tax management.
[0034] Through system 10 , stocks may be allocated and selected by a stratified sampling within a sector. The selected stocks may then be equally overweighted, thus avoiding overly-large active bets on one stock versus another. Loss harvesting and rebalancing may be performed at quarter end dates. If the portfolio holds a security that is deleted from the index, additional rebalancing may occur on that date. Both loss harvesting and rebalancing may be controlled by thresholds.
[0035] FIG. 2 shows a process 100 for allocating and selecting securities. Process 100 is for example implemented by software 14 , FIG. 1 . Briefly, in step 101 , net assets are calculated. In step 102 , cash is reserved in a buffer. An example of step 102 is to reserve the cash for exchange traded funds (EFTs). In step 103 , non-indexed securities are sold. In step 104 , loss harvisting is performed. Step 104 is for example implemented when stock prices decline by X% or more; for example X is five (5).In step 105 , new stocks are determined for a portfolio. In step 106 , weightings (e.g., equal overweighting) and cash distributions are set in the portfolio.
[0036] By implementing process 100 , a portfolio may continue to track an index despite the sale securities that were originally desired but which can no longer be purchased due to wash sale restrictions. Accordingly, through system 10 an initial portfolio may be constructed such that, if harvested, there would be suitable securities available to minimize tracking differences to the index. For example, an initial portfolio with the largest stocks may track the index reasonably well, but, upon harvesting, a porfolio is createed with smaller stocks.
[0037] Additional exemplary detail of steps 101 - 106 are now described. In step 101 , Net Assets are the sum of the current market value of securities and cash in a portfolio. The cash component includes all dividends earned during the period (applies only to existing portfolios). For initial portfolios, the net assets may use a starting value of $100,000.
[0038] In step 102 , accounts may hold reserve cash for fees (e.g., 1% of portfolio value) and/or for ETFs, for example. Using ETFs results in lower active risk (because ETFs nearly track an index perfectly) but will also result in lower tax alpha. Each percentage increase in ETFs reduces the standard deviation of tracking differences by the same percentage, but also reduces the tax alpha by a similar percentage. So, for example, if a portfolio without ETFs has a standard deviation (active risk) of 3.0% and an average tax alpha of 2.0%, holding ETFs at 10% of the portfolio reduces the active risk to about 2.7% and reduces the tax alpha to about 1.8%. System 10 and/or process 100 by therefore reserve cash for ETFs for any of the following three purposes: to create, by proxy, a tracking portfolio with substantially fewer stocks than the benchmark's 1500; to decrease tracking differences, for example by holding 10% of the portfolio in ETFs; and/or to manage cash.
[0039] In step 103 , once cash and ETF balances are reserved, non-index securities are sold. This is customizable if, for example, a user requires only tax-free transitioning or restricts the sale of certain securities. If all non-index securities are sold as of the last day within the index, for example, closing prices and applied transaction costs of 35 basis points may be applied to represent the spread.
[0040] In step 104 , securities that reach a desired loss harvesting threshold are sold. Harvesting is for example performed if sufficiently exceeding estimated costs of the trade. One exemplary threshold for harvesting occurs when the estimated tax benefit exceeded 175 basis points times the market value of the trade (this is approximately a price depreciation of 5%). The tax benefit may be estimated by multiplying the unrealized capital loss by the appropriate combined tax rate. The loss harvest threshold is met, in this example, when the tax rate x unrealized capital loss>1.75% times the market value. The tax rate may be determined per lot using long-term or short-term capital gains tax rates. If there are no securities in the portfolio (as in an initial portfolio), this step may be skipped.
[0041] In step 105 , the Global Industry Classification Standard (GICS) may be used to divide the index into its ten (10) sectors. The portfolio stocks are allocated to each sector in roughly the same proportions. Mathematically, they may be adjusted to ensure that each sector has at least one stock and rounded to whole numbers as in the following algorithmic example: Initial number of stocks per sector=Round down (# stocks per sector index/# stocks in index)−(number of desired stocks in portfolio−number of sectors)+1. This algorithmic example typically results in fewer than the total desired number of stocks. The sectors may then be sorted by ascending initial number of stocks per sector and descending sector index market capitalization. One stock may be added per sector, from top to bottom, until the total number of stocks allocated reaches the total desired number; this yields the adjusted number of target stocks per sector in the portfolio, in this example.
[0042] Continuing with step 105 , each sector in the index is then divided into tranches. In an exemplary embodiment, the number of tranches per sector is equal to the greater of four or the number of portfolio stocks allocated. (referred to herein as “Flex Min Bucketing”). Stocks may be sorted in descending weight within each sector, and then divided into tranches, where each tranche is split at 1 divided by the number of desired tranches. If for example five tranches are desired, the breakpoints are for every 20% in cumulative weight. Because the cumulative weight does not fall exactly on a breakpoint, only the cumulative weight less than the next breakpoint is included in the tranche. The stock where the cumulative weight is greater than the breakpoint falls into the next tranche. Hence, for example, instead of tranches at the 20%, 40%, 60%, 80%, and 100% cumulative weight marks, they may instead be at 18.8%, 38.3%, 59.6%, 78.5%, and 100% (in this example; all stocks that do not fit into the second to last tranche automatically fall into the last tranche).
[0043] Continuing with step 105 , once a desired target number of stocks per sector and the associated tranches are known, stocks are selected. In selecting stocks, all stocks remaining in the portfolio after loss harvesting and selling non-index constituents are first added to the rebalanced portfolio. Each of these becomes the selected stock for their respective tranche. For example, if five stocks are desired and three remain in the portfolio after loss harvesting and selling non-index securities, they will be added to the new portfolio. If these stocks are in the first, third, and fifth tranches, additional securities will not be added into those tranches. Additional stocks may be added to the portfolio if stocks are missing from their target tranche, but extras may not be removed. In this case, a new stock would be added to the second and fourth tranches.
[0044] If additional stocks are to be added, they may adhere to the following rules. In the first tranche, the largest stock is selected (but if there is already a stock in the tranche, no new stock need be selected, so the stock in the new portfolio may not be the largest stock. If the largest stock is restricted (due to wash sale rules or client restrictions, for example), then the next largest unrestricted stock is selected. If there are no other available candidates in the first tranche (e.g., it may have only one harvested stock, or it may have all restricted stocks), then the next largest stock is chosen, regardless of how far down it needs to search in subsequent tranches. For stocks initially targeted in tranches other than the first, the stock closest to the mean of the cumulative weight of the trance may be selected. If restricted, the next closest stock may be chosen. If no stock is available in its tranche, it may look to the closest to the mean stock in the next lower tranche. If no stock is available in the last tranche, then no stock may be chosen.
[0045] Due to market movement and index reconstitution, portfolios may have multiple securities falling into the same tranche over time. For example, if five stocks are desired and three stocks remain in the portfolio, after loss-harvesting, it would appear that two more stocks would be purchased; however, more stocks may actually be purchased in this case depending on which trances the existing stocks are in. If two of the three remaining stocks are in the first trance and the third is in the third tranche, then the strategy may for example choose one new stock in each of the second, fourth, and fifth tranches, resulting in six total stocks in the new portfolio. If strict adherence to the total number of desired target stocks is maintained, more stocks may be sold (e.g., those that have shifted tranches from the prior rebalance), thereby increasing turnover and capital gains; alternatively, tranches in this case may be left unfilled, disrupting the portfolio's ability to track an index. As neither of these scenarios is desirable, the portfolio sizes may be allowed to float.
[0046] In step 106 , weights the selected stocks. An incorrect weighting may cause substantial tracking differences to an index. For example, the S&P 500 and S&P Equal Weight Indexes have the same constituents, but substantial tracking error to one another. Accordingly, in step 106 , portfolios are weighted to be sector neutral. For example, if Financials are 23% of the index, then they will be 23% of the portfolio. The target weight for each stock within a sector may be equal to the stock's index weight within the sector, plus an overweight. By using only a subset of the index securities in the portfolio, some or all of the selected stocks may be overweighted. The overweight amount may be the same for all stocks and determined by the sum of the security weights within a sector for those securities not chosen to be in the portfolio; this figure is then divided by the number of target stocks in the sector. For example, the sum of the index weights of the chosen securities within a sector may be 80%, leaving 20% of the weight in the sector to be equally distributed among five stocks. Thus, each of the stocks, in this example, receives 20%/5=4% overweight. If a selected stock has an index weight of 18% of a sector, its weight in the portfolio will be 22%. Likewise, if a selected stock has an index weight of 1%, its weight in the portfolio will be 5%.
[0047] A current stock may be restricted from purchasing due to wash sale rules (there may be multiple lots per stock, and only those lots that exceed threshold may be harvested), in which case no further shares may be purchased. The cash that would have been distributed to the stock may be redistributed. A priority may be to keep the cash in the same sector first and then redistribute the cash evenly amongst the other unrestricted stocks. If all stocks are restricted, then the cash may be redistributed across the other sectors.
[0048] Since stocks in the portfolio may be misweighted versus their target, buy and sell tolerances may be used to avoid excessive rebalancing. While rebalancing maintains a well-constructed index-based portfolio and manages active risk, there is a tradeoff between tracking and transaction costs. Thus, securities that are overweighted by more than 1.5% versus their target may be sold down to their target weights. Likewise, small purchases for rebalancing may be limited if they increase turnover. When securities in gain positions are sold for rebalancing purposes, they may be sold by lot in order of minimizing taxes using respective long-term or short-term tax rates and applying them to losses before gains.
[0049] It should be apparent to those skilled in the art that there are many alternatives to distributing where and how to overweight. Overweighting nonethless may provide several advantages over cap weighting or tranche weighting (e.g., setting the weight of each of 5 stocks to 20%). For example, cap weighting forces the largest absolute percentage overweight to the largest names, possibly reducing the weight of the smallest names to the point that they round to 0 or some other impractically small amount. Using tranche weighting on the other hand artificially increases the weight of the smallest names, essentially creating an equal weighted portfolios within sectors which would poorly track a cap weighted index.
[0050] FIG. 3 , FIG. 4 , FIG. 5A , FIG. 5B , FIG. 5C , FIG. 6 , FIG. 7A , FIG. 7B , FIG. 7C , FIG. 7D , FIG. 7E , FIG. 7F , FIG. 8A , FIG. 8B , FIG. 9A , FIG. 9B , FIG. 10A , FIG. 10B , FIG. 11A and FIG. 11B illustrate another embodiment of processes suitable to select and manage securities; such processes are for example implemented by system 10 of FIG. 1 , such as through operations by software 14 . FIG. 3 shows a rebalancing process 1000 . FIG. 4 shows a harvesting process 1100 . FIG. 5A-5C shows a rebalancing process 1200 . FIG. 6 shows a lot harvesting process 1300 . FIG. 7A-7F show a stock selection process 1400 . FIG. 8A-8B show an invest remaining portfolio value process 1600 . FIG. 9A-9B show a loop content process 1700 . FIG. 10A-10B show a select representative constituents process 1800 . FIG. 11A-11B show a loop content two process 1900 .
[heading-0051] BACKTEST EXAMPLE
[0052] The following describes a backtest which confirms delivery of superior, after tax performance versus the S&P 500 by applying tax loss harvesting on an index-based account generated by system 10 and employing processes such as described in connection with FIG. 1-15 . While index funds tend to be tax efficient by their nature of low turnover, their after tax returns still tend to be less than their pre-tax returns. But using the above-descrived methodology (described in connection with FIG. 1 and 2 , for example) results in after tax returns that are greater than pre-tax returns.
[0053] The benchmark results utilized portfolios with 50, 100, 150, 200, and 250 initial stocks, 1% cash holdings, and include estimated transaction costs of 35 basis points on all trades. They do not include additional wrap or management fees.
[0054] This backtest used the S&P 500 as the benchmark. Portfolios were run beginning Dec. 31, 1994 through Dec. 31, 2002 with a new portfolio starting each month, yielding 96 portfolios and 3655 rolling twelve-month observations: The portfolio beginning Dec. 31, 1994 has 85 rolling twelve-month periods, beginning Jan 31, 1995 has 84 rolling twelve-month periods, and so on. Table 1 shows these results for any given twelve month period:
TABLE 1 Rolling 12 Month periods (out of 3655 observations): 50 Base 50 Stocks 100 Stocks 150 Stocks 200 Stocks 250 Stocks Pre-Tax Average Tracking Difference 0.16% −0.81% −0.61% −0.17% 0.14% 0.47% Median Difference 0.13% −0.62% −0.45% −0.08% 0.20% 0.46% Standard Deviation 3.21% 3.54% 2.61% 2.16% 2.08% 2.07% Most Underperforming 12 Month Period −11.10% −15.61% −9.99% −7.63% −9.76% −9.56% Most Overperforming 12 Month Period 9.57% 10.28% 9.27% 11.28% 8.59% 9.62% Probability of Underperforming > 0.5% 42.05% 51.63% 49.03% 41.45% 34.97% 28.48% Probability of Underperforming > 3.5% 11.35% 19.53% 13.65% 6.43% 4.24% 3.01% Probability of Underperforming > 5.5% 4.46% 9.96% 3.72% 1.56% 1.01% 1.18% Post-Tax Average Tracking Difference −0.75% 2.11% 2.57% 2.99% 3.38% 3.70% Median Difference −0.65% 2.28% 2.44% 2.63% 2.87% 3.11% Standard Deviation 3.20% 4.03% 3.30% 3.13% 3.24% 3.35% Most Underperforming 12 Month Period −12.96% −14.17% −7.86% −4.13% −4.77% −6.74% Most Overperforming 12 Month Period 8.11% 15.14% 16.09% 20.06% 19.10% 20.18% Probability of Underperforming > 0.5% 52.37% 24.57% 17.26% 9.74% 6.68% 4.46% Probability of Underperforming > 3.5% 16.63% 8.15% 2.65% 0.25% 0.25% 0.19% Probability of Underperforming > 5.5% 6.89% 3.34% 0.33% 0.00% 0.00% 0.08% Tax Alpha Average Tax Alpha −0.91% 2.92% 3.18% 3.16% 3.24% 3.24% Median Tax Alpha −1.05% 2.48% 2.82% 2.59% 2.62% 2.60% Standard Deviation 1.14% 3.00% 2.67% 2.46% 2.34% 2.31% Worst Case Tax Alpha −5.28% −2.58% −1.84% −0.52% 0.29% 0.02% Best Case Tax Alpha 2.55% 16.31% 15.45% 15.99% 15.70% 14.81% Probabilityof Tax Alpha > 0.5% 12.28% 73.21% 84.51% 95.76% 98.91% 99.21% Tracking Statistics R-Squared 97.53% 97.09% 98.35% 98.87% 98.99% 99.05% Correlation 0.9876 0.9853 0.9917 0.9943 0.9949 0.9953 Beta 0.9966 1.0074 0.9922 0.9787 0.9698 0.9589 50 Base: 50 Stocks, No Loss Harvesting, No Transaction Costs, 1% Cash The other cases use loss harvesting, 35 bps transaction costs, 1% Cash
[0055] The following observations and findings are determinable from the backtest:
Excluding transaction costs and loss harvesting, a 50 stock portfolio tracks an index pre-tax with a standard deviation of 3.2%. Increasing the number of stocks in the portfolio results in smaller tracking differences (active risk) pre-tax. Tax alpha from loss harvesting varies substantially depending on the date of the initial investment and the subsequent market conditions. Pre-tax active risk for a 50 stock portfolio is about 3.5%; for 100 stocks portfolios it is about 2.6% and falls to about 2% at 200 stocks. Loss harvesting opportunities are greater in declining, volatile markets. Tax alpha in any twelve month period may range from about −2.6% to +16.3%, with an average of 2-3%. The probability of a tax alpha greater than 0.5% in any twelve month period is 73% for a 50 stocks, 85% for a 100 stocks, 96% for 150 stocks, and 99% for 200 and 250 stocks. In rising markets, tax alpha may be negative due to rebalancing the portfolio with positions in capital gains. There is a trade-off between minimizing tracking differences, maximizing tax alpha, and minimizing costs. The strategy provides upside market gains with downside post-tax protection. Adding ETFs to a portfolio proportionately reduces the active risk, but it also proportionately reduces the tax alpha. Pre-tax underperformance is expected due to including transaction costs and the assumption of holding 1% in cash. Roughly 25 basis points per year are attributable to transaction costs and another 15 basis points per year for cash drag.
[0068] The “50 Base” portfolio of Table 1 shows that process 100 tracks an index closely using stratified sampling. This base case used 50 stocks with no transaction costs and no loss harvesting. Rebalancing was done quarterly for risk management purposes only. Such a portfolio track a pre-tax index with a standard deviation of 3.2% over the observed time period. The observed time period included extremely volatile markets up and down, yet the base case portfolio had an r-squared of 98%, correlation of 0.99, and a beta of nearly 1. As a point of reference, the 50 stock S&P 500 portfolio has a predicted tracking error of 2.6% using Barra as of Dec. 31, 2003.
[0069] The backtest also illustrated tradeoffs between the otherwise conflicting goals of high correlation and maximizing tax alpha. Ideally, the “best” portfolio tracks the index with perfect correlation on a pre-tax basis, while maximizing loss harvesting, and, hence, maximized after-tax returns. However, harvesting losses require portfolio rebalancing, thereby incurring transaction costs and portfolio weighting to something less than ideal (if, for example, minimizing pre-tax tracking were the only concern). This in turn may lead to greater tracking variances. If priority is placed on minimizing tracking differences, it would require holding more stocks and forgo loss harvesting, thus reducing post-tax alpha.
[0070] Parameters may therefore be selected to balance these opposing objectives; these parameters include, but are not limited to: sell tolerances, buy tolerances, loss harvesting thresholds, transaction costs, cash balances, ETF holding levels, initial number of stocks, and tax rates.
[0071] Note that the backtest included transaction costs (spread) of 35 basis points for every trade, and assumed holdings of about 1% in cash to avoid overdrawing the accounts and to reserve for payments of fees. Further, the backtest used only a whole number of shares. The backtest was therefore realistic of actual transactions.
[0072] In the backtest, portfolios of all sizes outperformed the index after tax if loss harvesting is used, yet they still tracked the index (pre-tax) with high r-squared and correlation figures and betas close to 1.
[0073] Indexing by system 10 , FIG. 1 , and process 100 , FIG. 2 , thus follows the market on a pre-tax basis (less transaction costs and cash drag), yet outperforms on a post-tax basis by tax loss harvesting. Loss harvesting involves realizing capital losses by selling securities that have declined in value. These losses may be used to offset capital gains inside or outside the portfolio for tax purposes. The end result is tax savings up to for example 41% on the amount of the realized capital loss. That is, for every $10,000 in capital losses realized, a user of system 10 may save roughly $4100 in taxes. The money raised from loss harvesting is used to buy new securities, or additional shares of existing securities, to construct a new index-based portfolio while obeying wash sale rules and user-specific restrictions.
[0074] Note that loss harvesting benefits do not eliminate taxes permanently, but rather defers the taxes into the future because proceeds generated from loss harvesting are reinvested into the portfolio, lowering the cost basis. Maximum benefit is realized if assets are passed on to an heir since they will receive a “step up” value in cost basis (i.e., the cost basis is reset to current market values, erasing unrealized capital gains). This is an enhanced version of a classic buy-and-hold strategy, which has a tangible tax benefit by deferring the realization of capital gains for as long as possible. But unlike a standard buy-and-hold strategy, loss harvesting actively realizes losses.
[0075] The backtest used data from Compustat's Expressfeed from S&P; but this data is somewhat different than the published index data. The main differences are in the shares outstanding and treatment of corporate actions. Expressfeed updates shares outstanding as they obtain the information. However, the S&P indexes only make immediate changes in shares outstanding when they are greater than 5%, to avoid excessive turnover from a practitioner's point of view. This timing difference creates artificial tracking errors in the backtest. With regard to corporate action, when an index constituent (e.g., Palm) spins off part of its company, a real shareholder will receive value (usually in the form of shares) for the new company (e.g., PalmSource). In Expressfeed data, the share price of the parent security falls by the value of the spinoff, but the value of the new security is not accounted for, making the portfolio appear to lose value. To adjust for this in the backtest, such spinoffs were treated as a dividend to the parent company. Not all such situations could be accounted for, however; for that reason, calculated indices trend slightly negative over time.
[0076] A shadow portfolio is a fully-replicating index portfolio, consisting of all stocks in the benchmark in their respective weights (essentially an index fund). All index additions and deletions were accounted for on the effective date of their changes. In the following description, shadow portfolios were allowed to hold fractional shares in order to avoid misweights due to rounding. All dividends and splits were captured and accounted for.
[0077] There are two main reasons in creating and using shadow portfolios as a benchmark. First, they are used to most accurately calculate an after-tax benchmark (no indexes currently report their performance figures after-tax), and, second, to have the capability to provide custom pre- and post-tax benchmark returns. For example, S&P does not construct an S&P 500 Ex-Technology or S&P 500 Ex-Tobacco index. When such a portfolio is needed, system 100 may manage and benchmark the portfolio.
[0078] For the most part, the shadow portfolios tracked the index total returns within 50 basis points due to a few small differences in data. As explained earlier, the main differences are the timing of shares outstanding updates and the treatment of spinoffs. Shadow benchmarking was used instead of the published index because it is most consistent with the data available for the backtest. Additionally, the shadow provides the most accurate representation of a benchmark for calculating post-tax comparable performance and subsequent tax alpha. While the shadow portfolios did not perfectly match the published index returns due to the limitations of the data, the backtested strategies were calculated based on the same data. Thus, the results of the backtest must only be compared to the performance of the shadow portfolios, not the published index.
[0079] During the backtest, on a pre-tax basis, portfolios were measured monthly for beginning to ending market value to calculate pre-tax returns. Transaction costs of 35 basis points were applied to all trades. On a post-tax basis, portfolio performance was calculated as the difference between the current period's after tax value and the prior end of month's pre-tax market value. The current month's after tax value was calculated by subtracting the estimated taxes from the current pre-tax value. A federal tax rate of 35% was applied to short-term capital gains. The tax rate used for dividends and long-term capital gains was 15%. Calculations also included a California tax rate of 9.3%. Combined effective tax rates were applied using the federal rate×Calif. state tax rate (1- federal tax rate) to account for the state tax deductibility for federal taxes. If there were net losses realized, this would result in negative taxes (tax savings) and higher after-tax performance. Net gains result in tax costs and lower after-tax performance. All tax benefits are applied to the portfolios in the month in which they occurred. This convention is consistent with AIMR after-tax reporting guidelines.
[0080] For purposes of the backtest, “tax alpha” (see Table 1) is defined as the difference between the post-tax tracking error and the pre-tax tracking error and may be positive or negative. Tax alpha in this definition is thus the net benefit (or cost, if negative) to the portfolio due to taxes. Pre-tax tracking error is the difference between the pre-tax performance of the portfolio and the shadow portfolio (the index as calculated). Post-tax tracking error is the difference between the post-tax performance of the portfolio and the shadow portfolio (the after-tax index, as calculated). The shadow portfolio used the same rules for applying taxes to realized capital gains/losses and dividends. Note that the shadow portfolio does not loss harvest and is representative of a full replication index fund.
[0081] In the backtest, simulated backtests were run beginning Dec. 31, 1994 (as far back as GICS codes have history) through Dec. 31, 2002. A new portfolio started at the end of each month for a total of 96 portfolios (8 years×12 portfolios/year). Simulations were run for 50, 100, 150, 200, and 250 stock initial portfolios. Returns and performance figures were measured for the composite and for the individual portfolios. Tracking differences were measured before and after tax versus the calculated index (shadow portfolio). Portfolios were loss harvested and rebalanced at calendar quarters (and when a holding was deleted from the index), use transaction costs of 35 bps per trade, have minimum purchases of $100 per trade, will sell securities with more than 1.5% in overweight, and target 1% in cash.
[0082] Measuring composite performance helps determine what the total performance is for all assets under management. Using the composite demonstrates how well short-term and long-term portfolios perform in up and down markets.
[0083] The backtest results suggest that the composite tracks the index well on a pre-tax basis. Portfolios of all sizes have high r-squares and correlation, with betas close to 1. The composites outperformed on a post-tax basis over time, though there are a few cases in single years where the composites underperformed their after-tax benchmark; these are because the tax alpha generated was not sufficient to make up for any pre-tax underperformance. The backtest composites had positive tax alpha every year for all portfolio sizes over the duration of this backtest.
[0084] Since portfolio performances in a composite offset one another, the standard deviations and range of the outliers tend to be smoothed over. Thus, the backtest considered the data two additional ways: 1) 8 full calendar year portfolios (i.e., Dec. 31, 1994-Dec. 31, 2002, Dec. 31, 1995-Dec. 31, 2002, etc.) to see how an investor would have performed if he had an initial investment at year-end, and 2) 96 individual portfolios analyzed in 3655 rolling twelve-month time periods. For full calendar years, the average portfolio has positive after-tax differences. The tax alpha generated for these portfolios more than made up for any pre-tax losses. In down markets, the outperformance post-tax tends to grow larger by actively loss harvesting. These results may be illustrated such as in FIG. 12 .
[0085] As mentioned above, loss harvesting is highly dependent upon the start date of the portfolio. The full-year simulations were run with start dates of December 31 of each year rolling forward for full years though Dec. 31, 2002. Note that for a portfolio starting Dec. 31, 1994 the tax alpha is actually negative. This is due to rebalancing the portfolio (for risk management purposes) while it is predominantly has capital gain positions due to large advances in the market. Tax alpha becomes positive in later years when the market if falling. The tax alpha in those years is less than if a portfolio were to begin in a down market because the cost basis for the Dec. 31, 1994 portfolio is lower, so the market needs to fall further before the equivalent amount of tax alpha can be generated.
[0086] Because the tax loss harvest benefit is highly dependent on the inception date (and thus cost basis) of the portfolio, simulations of the backtest were also run with a new portfolio starting every monthend beginning Dec. 31, 1994 and running through Dec. 31, 2002. Using this data, performance that any individual investor might see over 12, 24, and 36 month periods was evaluated. For the time period of the data, there were 85 portfolios with 12 months or more of data, yielding 3655 data points. The portfolio beginning Dec. 31, 1994 had 85 rolling 12-month periods; the portfolio beginning Jan. 31, 1995 had 84 rolling 12-month periods and so on. There were 2701 data points with 24-month rolling periods and 1891 data points with 36-month rolling periods.
[0087] In the benchtest, it was shown that although a pre-tax portfolio may not track the pre-tax index perfectly in any given year, it will get closer on an annualized basis over time. Likewise, increasing the number of stocks in a portfolio decreases the active risk. See FIG. 13 . Also, holding fewer stocks achieves the same distribution as a portfolio with more stocks if you hold it for a longer period of time. See FIG. 14 . For example, the distribution curve for 50 stocks annualized over 36-month periods is very similar to that of 100 stocks annualized over 24-month periods or 150 stocks over 12-month periods. What this means is that you will eventually end up in about the same place, regardless of size, but you'll need to hold your portfolio longer with a fewer number of stocks. The longer your time horizon, the less size matters pre-tax.
[0088] The benefit of loss harvesting rises when going from 50 to 150 stocks, but then tends to flatten out, due to having suitable stocks to reinvest in after harvesting. If the portfolio gets too large, it may result in “lockup,” where there are no other stocks to buy without violating wash sale rules. See FIG. 15 .
[0089] The following statistical definitions were used with the benchtest:
Beta: The measure of systematic risk of a security. Beta (or beta coefficient) is a means of measuring the volatility of a security or portfolio of securities in comparison with the market as a whole. Beta is calculated using regression analysis. A beta of 1 indicates that the portfolio's change in value will move with the market. A beta greater than 1 indicates that the portfolio's change in value will be more volatile than the market. A beta less than 1 means that it will be less volatile than the market. Correlation: A measure that determines the degree to which two variable's movements are associated. The correlation coefficient is calculated as:
ρ xy = Cov ( r x , r y ) σ x σ y
The correlation coefficient will vary from −1.0 to 1.0. −1.0 indicates perfect negative correlation, and 1.0 indicates perfect positive correlation.
Standard Deviation: A measure of the dispersion of a set of data from its mean. The more spread apart the data is, the higher the deviation. In finance, standard deviation is applied to the annual rate of return of an investment to measure the investment's volatility (risk).One standard deviation away from the average accounts for somewhere around 68 percent of the annual returns in the time period. Two standard deviations away from the mean account for roughly 95 percent of the annual returns. And three standard deviations account for about 99 percent of the annual returns. R-Squared: A statistical measure that represents the percentage of a portfolio's movements that are explained by movements in a benchmark index. R-squared values range from 0 to 1. A higher R-squared value will indicate a more useful beta figure. A low R-squared means you should ignore the beta. | A system, method and software product describe a customizable, index-based stock management methodology. This methodology provides for diversification and risk control of indexing combined with individual customization and active tax management. The system employing the methodology permits individual investors to invoke investment processes that track indexes to gain specified market exposure, control risk, and minimize costs while invoking individual preferences, current holdings, or social concerns | 49,887 |
RELATED APPLICATION DATA
This application is a continuation of U.S. patent application Ser. No. 09/452,021, filed Nov. 30, 1999 (now U.S. Pat. No. 7,044,395). The Ser. No. 09/452,021 application is a continuation-in-part of application Ser. No. 09/130,624, filed Aug. 6, 1998 (now U.S. Pat. No. 6,324,573). The Ser. No. 09/452,021 application is also related to application Ser. No. 08/508,083, filed Jul. 27, 1995 (now U.S. Pat. No. 5,841,978).
The Ser. No. 09/452,021 application is also a continuation-in-part of each of application Ser. No. 09/292,569, filed Apr. 15, 1999 (abandoned), Ser. No. 09/314,648, filed May 19, 1999 (U.S. Pat. No. 6,681,028), and Ser. No. 09/343,104, filed Jun. 29, 1999 now abandoned.
The Ser. No. 09/452,021 application also claims the benefit of U.S. Provisional Application Nos. 60/158,015, filed Oct. 6, 1999, 60/163,332, filed Nov. 3, 1999, and 60/164,619, filed Nov. 10, 1999.
This application is related to application Ser. No. 09/452,023, filed Nov. 30, 1999 (now U.S. Pat. No. 6,408,082) and Ser. No. 09/452,022, filed Nov. 30, 1999 (now U.S. Pat. No. 6,959,098). The technology disclosed in this application can advantageously be used in the methods and systems disclosed in the foregoing patents and applications (all of which are incorporated by reference).
TECHNICAL FIELD
The disclosure relates to embedding and reading machine-readable codes on objects, audio and video.
BACKGROUND AND SUMMARY
There are a variety standard ways to encode information in a machine-readable code that is either affixed to or applied to the surface of a tangible object. Perhaps the most widespread form of machine-readable code is the barcode, but there are many others. Other forms of machine-readable identification include magnetic stripe, magnetic ink character recognition (MICR), optical character recognition (OCR), optical mark recognition (OMR), radio frequency identification (RF/ID) etc.
While these forms of machine-readable identification are widely used and effective for many applications, they all have the disadvantage that they must occupy a dedicated portion of the physical object that they reside on. For example, if one wishes to apply a barcode or magnetic stripe to an object, the physical implementation of the code must occupy some portion of the object's surface apart from the other information content on the object. For some applications, this limitation does not pose a problem. For many applications, however, the need to locate the code on a dedicated portion of the object is a significant drawback. One drawback is that it requires the user to position the object so that the portion carrying the code can be read. Another drawback is that the code is not aesthetically pleasing, and may detract from the overall appearance of the object. In addition, the placement of the code may require an expensive and cumbersome manufacturing and application process.
Another characteristic of these forms of machine-readable identification is that they are perceptible to the users of the object. Again, for many applications, this characteristic is not a concern, and may in fact be a benefit. In some cases, however, it is a disadvantage for the code to be visually perceptible. As noted above, one drawback is that it detracts from the aesthetic appearance of the object. Another drawback is that it may be more likely to be tampered with.
Watermarks provide an alternative machine-readable code that addresses some or all of these drawbacks. Watermarks may be embedded in the information content (e.g., an image or graphics) or texture of an object's surface, and thus, do not require a separate, dedicated portion of the surface area. While some forms of image watermarks are visible, others may be embedded in image content such that they are virtually imperceptible to the user, yet readable by a machine.
In the following detailed description, watermarks and related machine-readable coding techniques are used to embed data within the information content on object surfaces. These techniques may be used as a substitute for (or in combination with) standard machine-readable coding methods such as bar codes, magnetic stripes, etc. As such, the coding techniques extend to many applications, such as linking objects with network resources, retail point of sale applications, object tracking and counting, production control, object sorting, etc. Object message data, including information about the object, machine instructions, or an index, may be hidden in the surface media of the object.
An object messaging system includes an embedder and reader. The embedder converts an object message to an object reference, and encodes this reference in a watermarked signal applied to the object. The reader detects the presence of a watermark and decodes the watermark signal to extract the object reference.
Further features and advantages will become apparent with reference to the following detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow diagram illustrating an overview of a watermarking embedding process.
FIG. 2 is a flow diagram illustrating an overview of a watermark reading process.
FIG. 3 is a diagram illustrating an image watermark embedding and reading system for marking objects.
FIG. 4 is a block diagram illustrating an implementation of an image watermark embedder.
FIG. 5 is a spatial frequency plot illustrating one quadrant of a detection watermark.
FIG. 6 is a flow diagram illustrating an implementation of an image watermark detector.
FIG. 7 is a flow diagram illustrating an implementation of an image watermark reader.
FIG. 8 is a diagram depicting an example of an image watermark detection process.
FIG. 9 is a diagram illustrating aspects of an image watermark reading process.
FIG. 10 is a system diagram illustrating an object messaging platform.
FIG. 11 is a diagram illustrating a computer system that serves as an operating environment for software implementations of watermark embedding and reading systems and object messaging applications.
DETAILED DESCRIPTION
Overview of Watermark System
The primary components of a watermarking system are an emdedder and a reader. The embedder encodes information into a watermark and applies it to an object, while the reader detects the watermark and decodes its information content. FIG. 1 is a flow diagram illustrating an overview of the embedding process. While advantageous to perform automatically, some of the steps may be performed manually, and may be implemented in distinct system components.
The process begins by obtaining an object message ( 100 ). In this context, an object message is a general term referring to information associated with an object, including object identifiers, an index to other information or instructions, and machine instructions. For example, the message may be a product identifier such as a Universal Product Code (UPC). For many applications, it is advantageous to leverage an existing object messaging scheme such as a UPC symbology, a magnetic stripe coding format, or some other extrinsic standard. However, it is also possible to develop a customized messaging scheme tailored to meet the demands of a particular application.
Next, the object message is converted into an object reference ( 102 ). The objective of this stage is to place the message in a data format suitable for transforming into a watermark signal. In some instances, the message may already be in a data format that can be directly converted to a watermark information signal (e.g., a binary number). In this case, there is no need to transform the object message into a different data format. In other instances, the object message may be expressed as a numeric or alphanumeric string representing some coded format. In this case, the embedding process decodes and transforms the message into a form suitable for conversion to watermark. This process may involve, for example, decoding and mapping each character or groups of adjacent characters into a binary number.
Next, the object reference is transformed into a watermark signal ( 104 ). The watermark signal defines how to manipulate the information content conveyed on the object's surface so as to place a watermark on the object. The specific details of this process depend on the nature of the watermark.
The watermark may be embedded in the information content of a digital image, for example. A digital image is comprised of a two or more dimensional array of image samples. In this case, the image sample values are manipulated to embed the watermark signal in the image. The term “image sample” refers generally to a discrete value in the image array. The image sample constitutes a value in any one of several domains, such as a spatial or frequency domain. In any given domain, image content may be represented in a variety of standard or custom formats or color spaces. A color space may have one or more dimensions. For example, a monochrome image typically has a single dimension representing a gray-scale value, while a color image typically has three dimensions, e.g., RGB (Red, Green, and Blue); or YUV (Luminance, and two Chrominance components).
While a digital watermark is typically applied to digital content, it may be implemented so as to remain with the content even through transformations to and from the analog domain. In addition to images, it applies to a variety of different media types, including audio and video.
The assignee's watermarking technology is reflected in U.S. Pat. No. 5,862,260 and laid-open PCT Application WO97/43736 (corresponding to U.S. patent application Ser. No. 08/746,613, now U.S. Pat. No. 6,122,403).
Another way to encode additional information in an image is in the form of a data glyph. An implementation of data glyphs is described in U.S. Pat. No. 5,315,098. Related visible watermarking work is illustrated in U.S. Pat. Nos. 5,706,364, 5,689,620, 5,684,885, 5,680,223, 5,668,636, 5,640,647, 5,594,809.
Alternatively, the watermark may be embedded in line graphics or text by varying the position of lines or characters in a manner that encodes the object reference.
In summary, watermarking can be applied to myriad forms of information. These include imagery (including video) and audio—whether represented in digital form (e.g., an image comprised of pixels, digital video, etc.), or in an analog representation (e.g., non-sampled music, printed imagery, banknotes, etc.). Watermarking can be applied to digital content (e.g. imagery, audio) either before or after compression (MPEG2, MPEG4, MP3). Watermarking can also be used in various “description” or “synthesis” language representations of content, such as Structured Audio, Csound, NetSound, SNHC Audio and the like (c.f. http://sound.media.mit.edu/mpeg4/) by specifying synthesis commands that generate watermark data as well as the intended audio signal.
Watermarking can also be applied to ordinary media, whether or not it conveys information. Examples include paper, plastics, laminates, paper/film emulsions, etc. A watermark can embed a single bit of information, or any number of bits.
The physical manifestation of watermarked information most commonly takes the form of altered signal values, such as slightly changed pixel values, picture luminance, picture colors, DCT coefficients, instantaneous audio amplitudes, etc. However, a watermark can also be manifested in other ways, such as changes in the surface microtopology of a medium, localized chemical changes (e.g. in photographic emulsions), localized variations in optical density, localized changes in luminescence, etc. The surface texture of an object may be altered to create a watermark pattern. This may be accomplished by manufacturing an object in a manner that creates a textured surface or by applying material to the surface (e.g., an invisible film or ink) in a subsequent process. Watermarks can also be optically implemented in holograms and conventional paper watermarks.
When determining how to implement this aspect of the embedder, there are a number of design objectives to consider. One objective to consider is the degree to which the watermark is imperceptible upon ordinary inspection. As the watermark becomes less perceptible, it may also become more difficult to detect and read accurately. Another objective is the quantity of information that one wishes to embed in the watermark. As the quantity of information increases, the watermark will need to support larger object references. Yet another objective is security. In some applications, it is desirable to employ an object reference scheme that makes the object references more difficult to decipher or remove from the objects.
Having created a watermark signal, the embedder creates the watermarked object ( 106 ). As referenced above, this process may involve printing or applying a watermarked image to the surface of the object, or texturing the surface of the object so as to impart the watermark to the object.
Once embedded in the object, the object reference serves as a machine-readable code that conveys information about the object, a machine instruction or instructions, or an index to information or instructions. Any compatible reader may extract the object reference. FIG. 2 is a flow diagram illustrating an overview of the reading process. Typically, the reader system incorporates a combination of hardware and software elements. First, the reader scans the object surface to capture a digital representation of the surface (e.g., an image, or map of surface topology) ( 200 ). Next, the reader processes the surface representation to detect whether a watermark is present ( 202 ). If so, the reader proceeds to read the watermark payload ( 204 ). In some implementations, a separate detection process is not performed.
Example Implementations of Digital Image Watermark Embedder and Reader
The following sections describe implementations of a watermark embedder and reader that operate on digital images. The embedder encodes the object reference into a digital image by modifying its image sample values such that the object reference is imperceptible to the ordinary observer in the output image. The embedder prints the output image on the surface of the object. To extract the object reference, the reader captures an image of the object and then processes it to detect the watermark and decode the object reference.
FIG. 3 is a block diagram summarizing image processing operations involved in embedding and reading a watermark. There are three primary inputs to the embedding process: the original, digitized image 300 , the object reference 302 , and a series of control parameters 304 . The control parameters may include one or more keys. One key may be used to encrypt the object reference. Another key may be used to control the generation of a watermark carrier signal or a mapping of information bits in the object reference to positions in a watermark information signal. Other parameters may include control bits added to the object reference, and a watermark detection pattern used to assist in the detection of the watermark. The watermark embedding process 306 performs a watermarking function on the object reference to convert it to a watermark information signal. It then combines this signal with the input image and the detection pattern to create a watermarked image 308 .
The watermark detector 310 operates on a digitized image captured from the marked object 312 . Using parameters 314 from the embedder (e.g., detection pattern, control bits, key(s)), it performs a series of correlation or other operations on the captured image to detect the presence of a watermark. If it finds a watermark, it determines its orientation within the image. After re-orienting the data, the reader 316 extracts the object reference. Some implementations do not perform correlation, but instead, use some other detection process or proceed directly to extract the watermark signal.
The Embedder
FIG. 4 is a block diagram illustrating an implementation of an embedder in more detail. The embedding process begins with the object reference 400 . As noted above, the object reference is binary number suitable for conversion to a watermark signal. For additional security, it may be encrypted with an encryption key 402 . In addition to the information conveyed in the object message, the embedder may also add control bit values to the object reference to assist in verifying the accuracy of a read operation. These control bits, along with the bits representing the object message, are input to an error correction coding process 404 designed to increase the likelihood that the object message can be recovered accurately in the reader.
There are several alternative error correction coding schemes that may be employed. Some examples include BCH (“trellis”) and convolution coding. These forms of error correction coding are sometimes used in communication applications where data is encoded in a carrier signal that transfers the encoded data from one place to another. In the digital watermarking application discussed here, the raw bit data is encoded in the fundamental carrier signal. Other forms of error correction coding include turbo codes.
In addition to the error correction coding schemes mentioned above, the embedder and reader may also use a Cyclic Redundancy Check (CRC) to facilitate detection of errors in the decoded object reference data.
The error correction coding function 404 produces a string of bits, termed raw bits 406 , that are embedded into a watermark information signal. Using a carrier signal 408 and an assignment map 410 , the embedder encodes the raw bits in a watermark information signal 412 , 414 . The carrier signal is essentially a noise image. For each raw bit, the assignment map specifies the corresponding image sample or samples that will be modified to encode that bit.
The embedder depicted in FIG. 4 operates on blocks of image data (referred to as ‘tiles’) and replicates a watermark in each of these blocks. As such, the carrier signal and assignment map both correspond to an image block of a pre-determined size, namely, the size of the tile. To encode each bit, the embedder applies the assignment map to determine the corresponding image samples in the block to be modified to encode that bit. Using the map, it finds the corresponding image samples in the carrier signal block. For each bit, the embedder computes the value of image samples in the watermark information signal as a function of the raw bit value and the value(s) of the corresponding samples in the carrier signal block.
To illustrate the embedding process further, it is helpful to consider an example. First, consider the following background. Digital watermarking processes are sometimes described in terms of the transform domain in which the watermark signal is defined. The watermark may be defined in the spatial domain, or some other transform domain such as a wavelet transform, DCT, Fourier transform, or Karhunen-Loeve transform (KLT) domain.
Now consider an example where the watermark is defined in the spatial domain and the tile size is 128 by 128 pixels. In this example, the assignment map specifies the corresponding sample location or locations in the tile that correspond to each bit position in the raw bits. In the spatial domain, the carrier signal looks like a noise pattern extending throughout the tile. Each image sample in the spatial domain of the carrier signal is used together with a selected raw bit value to compute the value of the image sample at the same location in the watermark information signal.
With this background, the embedder proceeds to encode each raw bit as follows. It uses the assignment map to look up the position of the corresponding image sample (or samples) in the carrier signal. The image sample value at that position in the carrier controls the value of the corresponding position in the watermark information signal. In particular, the carrier sample value indicates whether to invert the corresponding watermark sample value. The raw bit value is either a one or zero. Disregarding for a moment the impact of the carrier signal, the embedder adjusts the corresponding watermark sample upward to represent a one, or downward to represent a zero. Now, if the carrier signal indicates that the corresponding sample should be inverted, the embedder adjusts the watermark sample downward to represent a one, and upward to represent a zero. In this manner, the embedder computes the value of the watermark samples for a raw bit using the assignment map to find the spatial location of those samples within the block.
From this example, a number of points can be made. First, the embedder may perform a similar approach in any transform domain. Second, for each raw bit, the corresponding watermark sample or samples are some function of the raw bit value and the carrier signal value. The specific mathematical relationship between the watermark sample, on one hand, and the raw bit value and carrier signal, on the other, may vary with the implementation. Third, the carrier signal may remain constant for a particular application, or it may vary from one message to another. For example, a secret key may be used to generate the carrier signal pattern. For each raw bit, the assignment map may define a pattern of watermark samples in the transform domain in which the watermark is defined. An assignment map that maps a raw bit to a pixel location or set of locations (i.e. a spatial map) is just one special case of an assignment map for a transform domain. Fourth, the assignment map may remain constant, or it may vary from one message to another. In addition, the carrier signal and map may vary depending on the nature of the underlying image. In sum, there many possible design choices within the implementation framework described above.
The embedder depicted in FIG. 4 combines another watermark component, shown as the detection watermark 416 , with the watermark information signal to compute the final watermark signal. The detection watermark is specifically chosen to assist in identifying the watermark and computing its orientation in a detection operation.
FIG. 5 is a spatial frequency plot illustrating one quadrant of a detection watermark. The points in the plot represent impulse functions (also referred to as grid points), indicating signal content of the detection watermark signal. The pattern of grid points for the illustrated quadrant is replicated in all four quadrants. There are a number of properties of the detection pattern that impact its effectiveness for a particular application. The selection of these properties is highly dependent on the application. One property is the extent to which the pattern is symmetric about one or more axes. For example, if the detection pattern is symmetrical about the horizontal and vertical axes, it is referred to as being quad symmetric. If it is further symmetrical about diagonal axes at an angle of 45 degrees, it is referred to as being octally symmetric (repeated in a symmetric pattern 8 times about the origin). Such symmetry aids in identifying the watermark in an image, and aids in extracting the rotation angle. However, in the case of an octally symmetric pattern, the detector includes an additional step of testing which of the four quadrants the orientation angle falls into.
Another criterion is the position of the grid points and the frequency range that they reside in. Preferably, the grid points fall in a mid frequency range. If they are located in a low frequency range, they may be noticeable in the watermarked image. If they are located in the high frequency range, they are more difficult to recover. Also, they should be selected so that scaling, rotation, and other manipulation of the watermarked signal does not push the grid points outside the range of the detector. Finally, the grid points should preferably not fall on the vertical or horizontal axes, and each grid point should have a unique horizontal and vertical location.
Returning to FIG. 4 , the embedder makes a perceptual analysis 418 of the input image 420 to identify portions of the image that can withstand more watermark signal content without substantially impacting image fidelity. Generally, the perceptual analysis identifies portions where there is more image activity. In these areas, the sample values are changing more than other areas and have more signal strength. The output of the perceptual analysis is a perceptual mask 422 that represents signal activity. For example, the mask may be implemented as an array of multipliers, which selectively increase the signal strength of the watermark information and detection signals in areas of greater signal activity.
The embedder combines ( 424 ) the watermark information and detection signals and then applies the perceptual mask to yield the watermark signal 426 . Finally, it combines ( 428 ) the input image 420 and the watermark signal 426 to create the watermarked image 430 . In the spatial watermark example introduced above, the embedder adds the image samples in the watermark signal to the corresponding samples in the input image to create the watermarked image 430 . In other implementations, the embedder may perform alternative functions to combine the watermark signal and the input image (e.g., multiplication). The net effect is that some image samples in the input image are adjusted upward, while others are adjusted downward. The extent of the adjustment is greater in areas of the image having greater signal activity.
The Detector and Reader
FIG. 6 is a flow diagram illustrating an overview of a watermark detection process. This particular approach performs a series of transforms and re-mappings of the image data 600 to enhance the efficiency of correlation processes used to search for the detection pattern in the target image. First, the detector transforms the image data to another domain 602 , namely the spatial frequency domain, and then performs a series of correlation or other detection operations 604 . The correlation operations match the detection pattern with the target image data to detect the presence of the watermark and its orientation parameters 606 (e.g., translation, scale, rotation, and differential scale relative to its original orientation). Finally, it re-orients the image data based on one or more of the orientation parameters 608 .
If a watermark is detected, the reader extracts the watermark information signal from the re-oriented image data. FIG. 7 is flow diagram illustrating a process of extracting the object reference information from the re-oriented image data 700 . The reader scans the image samples (e.g., pixels) of the re-oriented image ( 702 ), and compares each one with its neighbors 704 . Recall that the embedder adjusted pixel values up or down to create the watermark information signal. The reader uses this attribute of the watermark to extract it from the target image. If an image sample value is sufficiently greater or less than its neighbors, then it is a candidate for further analysis in the reading process. As such, the reader evaluates the value of the image sample relative to its neighbors to determine how it differs from its neighbors. If the difference is significant, then the sample is a candidate for containing some portion of the watermark signal.
For each such candidate, the reader uses the assignment map to find the corresponding raw bit position and image sample in the carrier signal ( 706 ). The value of the raw bit is a function of how the candidate differs from its neighbors, and the carrier signal at the corresponding location in the carrier. For instance, in the example provided above, the carrier signal indicates whether to invert the bit value, while the difference between the candidate and its neighbors indicates whether the bit value should be interpreted as a one or zero. As reflected generally in FIG. 7 ( 708 ), the result of this computation represents only one vote to be analyzed along with other votes impacting the value of the corresponding raw bit. Some votes may indicate that the raw bit is likely to be a one, while others may indicate that it is a zero. After the reader completes its scan, it compiles the votes for each bit position in the raw bit string, and makes a determination of the value of each bit at that position ( 710 ). Finally, it performs the inverse of the error correction coding scheme to construct the object reference ( 712 ). In some implementations, probablistic models may be employed to determine the likelihood that a particular pattern of raw bits is just a random occurrence rather than a watermark.
Example Illustrating Detector Process
FIG. 8 is a diagram depicting an example of a watermark detection process. the detector segments the target image into blocks (e.g., 800 , 802 ) and then performs a 2-dimensional fast fourier transform (2D FFT) on each block. This process yields a 2D transform of the magnitudes of the image content of the block in the spatial frequency domain as depicted in the plot 804 shown in FIG. 8 .
Next, the detector process performs a log polar remapping of the transformed block. The type of remapping in this implementation is referred to as a Fourier Mellin transform. The Fourier Mellin transform is a geometric transform that warps the image data from a frequency domain to a log polar coordinate system. As depicted in the plot 806 shown in FIG. 8 , this transform sweeps through the transformed image data along a line at angle θ, mapping the data to a log polar coordinate system shown in the next plot 808 . The log polar coordinate system has a rotation axis, representing the angle θ, and a scale axis. Inspecting the transformed data at this stage, one can see the grid points of the watermark begin to be distinguishable from the noise component (i.e., the image signal).
Next, the detector performs a correlation 810 between the transformed image block and the transformed grid 812 . At a high level, the correlation process slides the grid over the transformed image (in a selected transform domain, such as a spatial frequency domain) and measures the correlation at an array of discrete positions. Each such position has a corresponding scale and rotation parameter associated with it. Ideally, there is a position that clearly has the highest correlation relative to all of the others. In practice, there may be several candidates with a promising measure of correlation. As explained further below, these candidates may be subjected to one or more additional correlation stages to select the one that provides the best match for the grid pattern.
There are a variety of ways to implement the correlation process. Any number of generalized matching filters may be implemented for this purpose. One such filter, referred to as a Fourier Magnitude filter, performs an FFT on the target and the grid multiplies the resulting arrays together to yield a multiplied FFT. The filtering operation is a form of convolution of the grid with the target image. In particular, the filter repeatedly re-positions, multiplies the corresponding samples of the grid and target, and accumulates the result at the corresponding location in the resulting array. Finally, it performs an inverse FFT on the multiplied FFT to return the data into its original log-polar domain. The position or positions within this resulting array with the highest magnitude represent the candidates with the highest correlation.
When there are several viable candidates, the detector selects a set of the top candidates and applies an additional correlation stage. Each candidate has a corresponding rotation and scale parameter. The correlation stage rotates and scales the FFT of the grid and performs a matching operation with the rotated and scaled grid on the FFT of the target image. The matching operation multiplies the values of the transformed grid with sample values at corresponding positions in the target image and accumulates the result to yield a measure of the correlation. The detector repeats this process for each of the candidates and picks the one with the highest measure of correlation. As shown in FIG. 8 , the rotation and scale parameters ( 814 ) of the selected candidate are then used to find additional parameters that describe the orientation of the watermark in the target image.
The detector applies the scale and rotation to the target data block 816 and then performs another correlation process between the grid 818 and the scaled and rotated data block 816 . The correlation process 820 is a generalized matching filter operation. It provides a measure of correlation for an array of positions that each has an associated translation parameter (e.g., an x, y position). Again, the detector may repeat the process of identifying promising candidates (i.e. those that reflect better correlation relative to others) and using those in an additional search for a parameter or set of orientation parameters that provide a better measure of correlation.
At this point, the detector has recovered the following orientation parameters: rotation, scale and translation. For many applications, these parameters may be sufficient to enable accurate reading of the watermark. In the read operation, the reader applies the orientation parameters to re-orient the target image and then proceeds to extract the watermark signal. In some applications, the watermarked image may be stretched more in one spatial dimension than another. This type of distortion is sometimes referred to as differential scale or shear. Consider that the original image blocks are square. As a result of differential scale, each square may be warped into a parallelogram with unequal sides. Differential scale parameters define the nature and extent of this stretching.
Differential Scale
There are several alternative ways to recover the differential scale parameters. One general class of techniques is to use the known parameters (e.g., the computed scale, rotation, and translation) as a starting point to find the differential scale parameters. Assuming the known parameters to be valid, this approach warps either the grid or the target image with selected amounts of differential scale and picks the differential scale parameters that yield the best correlation.
Another approach to determination of differential scale is set forth in application Ser. No. 09/452,022 (now U.S. Pat. No. 6,959,098).
Example Illustrating Reader Process
FIG. 9 is a diagram illustrating a re-oriented image 900 superimposed onto the original watermarked image 902 . The original watermarked image is sub-divided into tiles (e.g., 128 by 128 pixel blocks 904 , 906 , etc.). When superimposed on the coordinate system of the original image 902 shown in FIG. 9 , the target image blocks typically do not match the orientation of the original blocks.
The reader scans each pixel of the re-oriented image, comparing its value to neighboring pixel values. If the pixel value is greater or less than its neighbors by some predetermined threshold, the reader determines its corresponding sample in the fundamental carrier signal. The assignment map indicates the corresponding sample in the fundamental carrier signal for each position in the re-oriented image. The carrier deduces a value of the corresponding raw bit based on: 1) whether the pixel value is greater than or less than its neighbor; 2) whether the corresponding carrier signal indicates that the value has been inverted. The deduced value becomes a vote for the value of the corresponding raw bit value, along with other values deduced from other pixels in the re-oriented image.
In one implementation, the embedder subdivides the original input image into tiles of 128 by 128 pixels. The object reference signal, before error correction encoding, is a total of 90 bits, including 4 bits specifying a generation number, 10 bits specifying message type, and 76 bits of message field. Through the error correction coding process, this 90 bit string becomes some greater number of bits (e.g., 128, 512, etc.).
Consider the case where there are 512 error-coded bits. Each of these 512 bits is distributed in a watermark signal in a tile. In particular, each raw bit maps to two positions in each of 16 sub-blocks (32 by 32 pixel blocks) within the tile. Note that there are 1024 pixel positions within a 32 by 32 block. Each one of the 512 bits maps to a unique pair of pixel positions within the sub-block. For each such pair of pixel positions, the carrier signal indicates that the watermark signal at one location will add to the original image, while the other will subtract from the original image. Knowing that the assignment map and fundamental carrier signal have these attributes, the reader directly computes the votes for each raw bit value as it scans through the re-oriented image.
The information encoded in the raw bit string can be used to increase the accuracy of read operations. For instance, in the implementation, some of the raw bits (e.g., 50-200 bits) perform a validity checking function. Unlike the object message information, the reader knows the values of these validity bits. The reader can assess the validity of a read operation based on the extent to which the extracted validity bit values match the expected validity bit values. The votes for a given raw bit value can then be given a higher weight depending on whether they are derived from a tile with a greater measure of validity.
Conversion of Standard Machine-Readable Codes to Digital Watermarks
Current machine-readable codes such as bar codes typically encode a numeric or alphanumeric character string. This string acts as an object message that may be used to encode a variety of information about the object with which it is associated. Just as this string can be implemented in existing machine-readable codes for objects, it can also be implemented in a digital watermark applied to objects. As a result, digital watermarks may be used as a replacement for a wide variety of applications currently using conventional machine-readable codes, e.g., according to extrinsic standards such as those established by ANSI, UCC, EAN, etc.
One typically starts the development of an object marking application by devising an object messaging scheme for encoding information within objects. The implementer may create a new messaging scheme or leverage existing object messaging schemes.
Bar Codes
Existing bar code messaging schemes may be used in object marking applications that employ digital watermarks as a replacement for bar codes. Over the years, a number of standards organizations and private entities have formed symbology standards for bar codes. Some examples of standards bodies include the Uniform Code Council (UCC), European Article Numbering (EAN, also referred to as International Article Numbering Association), Japanese Article Numbering (JAN), Health Industry Bar Coding Counsel (HIBC), Automotive Industry Action Group (AIAG), Logistics Application of Automated Marking and Reading Symbols (LOGMARS), Automatic Identification Manufacturers (AIM), American National Standards Institute (ANSI), and International Standards Organization (ISO).
The UCC is responsible for the ubiquitous bar code standard called the Universal Product Code (UPC). AIM manages standards for industrial applications and publishes standards called Uniform Symbology Standards (USS).
Some well know bar code schemes include UPC and UCC/EAN-128, Codabar developed by Pitney Bowes Corporation, I 2 of 5 and Code 128 developed by Computer Identics, Code 39 (or 3 of 9) developed by Intermec Corporation, and code 93.
Some bar codes, such as UPC, are fixed length, while others are variable length. Some support only numbers, while others support alphanumeric strings (e.g., Code 39 supports full ASCII character set). Some incorporate error checking functionality.
While the bar codes listed above are generally one dimensional in that they consist of a linear string of bars, bar codes may also be two-dimensional. Two dimensional bar codes may be in a stacked form (e.g., a vertical stacking of one-dimensional codes), a matrix form, a circular form, or some other two-dimensional pattern. Some examples of 2D barcodes include code 49, code 16k, and PDF-417. All of the above bar code schemes encode a relatively small amount of information and may be converted into watermark signals using the method outlined in FIG. 1 .
For more information on bar codes, see D. J. Collins, N. N. Whipple, Using Bar Code-Why It's Taking Over, (2d ed.) Data Capture Institute; R. C. Palmer, The Bar Code Book, (3 rd ed.) Helmers Publishing, Inc., and P. L. Grieco, M. W. Gozzo, C. J. Long, Behind Bars, Bar Coding Principles and Applications, PT Publications Inc., which are hereby incorporated by reference.
Other Machine Readable Codes
Other forms of machine-readable identification include, for example, magnetic stripe, magnetic ink character recognition (MICR), optical character recognition (OCR), optical mark recognition (OMR), radio frequency identification (RF/ID) etc. The information encoded in these forms of machine-readable identification may be converted into watermark signals using the method outlined in FIG. 1 .
Basic Platform Structure
FIG. 10 is a block diagram illustrating an object identification and messaging platform that supports a variety of applications discussed below. The basic elements of an object messaging system include a reader device 1000 (e.g., a scanner or camera), a data processing unit 1002 connected to the reader (the reader unit), and in some applications one or more remote data processing units 1004 , 1006 interconnected with the reader unit 1002 via a communication network 1008 . The object messaging system includes one or more reader units, such as the reader—processing unit ( 1000 , 1002 ) pair shown in FIG. 10 . It may also include one or more embedder units comprising a data processing unit 1010 and printer 1012 . The reader units scan and interpret the watermark signal on a watermarked object 1014 (e.g., label, tag, packaging, card, document, product, etc.). The embedder units embed the watermark signal in the object 1014 . For example, the embedder prints a watermarked image on the object to create a watermarked object.
Each of the data processing units typically is associated with a data store ( 1020 - 1026 ). The data store is used to store a variety of data associated with a messaging application such as object messages, object references, and cross-referencing between the object messages, references and other object related data. The data store may be configured as a database using conventional database management software and data structures, such as a relational, hierarchical, or object oriented database, to name a few. In addition, the data store may be used to store the various control parameters associated with reading and embedding operations, such as encryption keys, assignment maps, detection maps, watermark carrier signals, etc. In some software applications, the data stores also store program code that implements reading and embedding functions.
The arrangement of functional units in FIG. 10 is not intended to depict a required structure of an object messaging system. The system components may be implemented using combinations of standard or custom hardware and software modules. The embedder unit may be implemented within a single device, such as an ink jet or laser printer equipped with an internal data processing unit or data store (e.g., microprocessor and memory sub-system with volatile and persistent storage devices.) Alternatively, the embedder unit may be implemented in separate components, such as a stand-alone printer connected to a computer system with a data processing unit and data store. Similarly, the reader unit may be incorporated into a single device, such as a digital camera equipped with a microprocessor and memory, or a combination of devices such as a computer and stand-alone scanner or camera.
Some applications may include sub-systems that serve as both readers and embedders with a data processing unit, data store, reader device (e.g., camera or scanner), and embedding device (e.g., printer).
The communication media interconnecting the various devices may vary as well. The communication media may be wire-based (e.g., cable, bus, discrete wiring) or wireless (radio frequency, microwave, infra-red, audio, etc.). The communication protocol governing the transfer of information (e.g., program code and data) depends on the underlying physical communication link and may encompass a variety of different standard or custom protocols.
Applications
The object message and its associated object reference embedded in a machine-readable code on an object may serve a multitude of functions. The following sections highlight some of these functions and illustrate them in the context of example applications.
Generally speaking, the function of the object reference may include any or all of: a source of information about the object, a machine instruction or set of instructions, a link or index to other information, etc.
As a source of information, the reference may identify the object through an object identifier. In addition, the reference may convey other information about the object, such as the owner, seller, buyer, manufacturer, service provider, transaction, a time or date identifier of a transaction, a location (e.g., geographic location or machine address), or monetary quantity (value, cost, price, etc.), license, terms of use, instructions for use, etc.
As a machine instruction, or set of instructions, the reference may instruct a local and/or remote data processing unit to perform some automated function, such as sending or requesting information, updating a database, launching an application program, controlling a machine action (e.g., a media recording or playback device, robot, printer, etc.). In a computer, for example, the reference may be interpreted by one computer program to execute one or more other programs. In addition, the reference may itself be a computer program that executes on the data processing unit of the reader unit or some remote data processing unit, and invokes one or more other programs.
In applications where the object is a machine, the object reference may also facilitate remote control and remote updating of control instructions for the machine. Consider examples where the object is a robot, portable or desktop computer, consumer electronic device (e.g., television, stereo component, etc.), telephone, embedded computer on board a vehicle or some other machine, appliance, etc. In such applications, the object includes an object reference, embedded in a machine-readable code. In response to scanning the object, a reader unit (such as the one depicted in FIG. 10 and described above) communicates with a server computer, either connected locally or remotely through a network (e.g., the Internet), and provides an object identifier.
The object identifier identifies the object to the server, and may also provide related information, such as its date of manufacture, its network address, a computer instruction or set of instructions, or an index to any of these types of information. The server computer returns a control instruction or set of instructions to the object via a computer communication link, such as a network connection. Alternatively, the server can instruct another computer to return these control instructions to the object. The communication link may be a wire link, wireless link or some combination of these links. For example, the control instructions may be sent via a network to a local computer, which in turn communicates them via a wire or wireless connection to the object. The reader unit may perform the function of receiving the control instructions from the server or other computer and communicating them to the object. The reader unit may be incorporated in the object itself, or may be a separate device that scans the object periodically so that it can be updated with the latest control instructions.
One form of these control instructions is a computer program that is downloaded into a memory device such as a RAM, ROM, or disk on the object. These types of objects are equipped with a processor (e.g., DSP, microprocessor etc.) to execute the instructions from the memory device. Another form of these control instructions is machine codes that control the functions of the device through hardware that is designed to respond to a predetermined set of machine codes. Yet another form of these control instructions are operating parameters that control the operating mode of the object (such as velocity, volume, flow rate, etc.).
As a link or index, the reference may provide a mechanism for accessing more information about the object (as described in the first category) or for accessing machine instruction or set of instructions (as described in the second category). For example, in some applications, it may difficult to encode a substantial amount of information about the object in the object reference itself. The index or link addresses this problem by enabling the object reference to refer to more information about the about, which may be stored in one location or distributed in a variety of locations (e.g., a central database, or a distributed database). There may be one or more layers of indirection in the linking or indexing scheme. For example, the object reference may be a unique identification number (UID) that cross-references a Uniform Resource Locator (URL) of a web page or email address, which in turn references an Internet Protocol (IP) address.
The object reference may be much more powerful by combining two or more of the functions described above. In addition, combinations of machine-readable codes, such as watermarks and conventional machine-readable codes, may be embedded on an object. Each of the codes may perform one or more of the functions noted above. Once read, the codes may perform independent functions or perhaps more interestingly, may interact to perform any of the functions listed above.
The object reference may be coded in some established coding format, compressed, and encrypted. For example, the object reference may be coded to be compatible with some way of encoding numbers, alphabetic characters, or a language. In addition, it may be encoded according to an error correction or data compression methodology. Finally, it may be encrypted for security purposes.
The following sections discuss some object messaging applications employing watermarks or other machine-readable codes.
Reference to Resource on a Computer Network
The object reference may serve as an address of or link to a resource on a computer network, such as a local area network (LAN) or wide area network (WAN), such as the Internet. Paralleling the functional framework outlined above, the reference may encode the network address of the network resource, an index to the address in a data store, or a computer instruction or set of instructions to access the resource located at the address.
Patents relating to the use of a bar code or other machine readable code to encode an index to a network address or an address of a computer resource on an object include: U.S. Pat. Nos. 5,463,209; 5,594,226; 5,640,193; 5,939,695; 5,848,413; 5,671, 282; 5,978,773; 5,933,829; 5,918,213; 5,665,951, 5,804,803, 5,971,277; 5,940,595; 5,930,767; 5,939,699; 5,938,726; 5,903,729; 5,902,353; 5,969,324; 5,918,214; 5,950,173; 5,963,916; 5,869,819; 5,905,248; 5,905,251; 5,979,757; 5,938,727; 5,913,210; and 5,841,978. These patents are hereby incorporated by reference.
Patent Applications relating to the use of machine-readable codes to link to a network resource include: U.S. Patent Application Nos. 60/082,228, 60/141,763, 60/158,015, 09/314,648 (U.S. Pat. No. 6,681,028), 09/342,688 (U.S. Pat. No. 6,650,761), 09/342,971 (pub. no. US 2003-0040957 A1), 09/342,689 (U.S. Pat. No. 6,311,214), 09/343,104 assigned to Digimarc Corporation, which are hereby incorporated by reference.
Foreign Patent Applications relating to the use of a machine readable codes to reference a network resource include: JP application 05-262400, published as JP 7115474 on May 2, 1995; Canadian Patent Application No. 2,235,002 (Counterpart of U.S. patent application Ser. No. 08/878,359, entitled “Network-Based Search Engine Using Scanner Codes,”; WO 98/40823; WO 98/49813; WO 99/34277; PCT application US97/21975, published as WO 98/24050; Japanese application 08-326318, published on Jun. 26, 1998, as JP 10171758; Japanese application 08-335992, published on Jun. 30, 1998, as JP 10177613, entitled Method And Device For Generating And Inputting URL; GB2327565A; WO98/14887 and WO98/20642; which are hereby incorporated by reference.
Related publications include: “Distributing Uniform Resource Locators as Bar Code Images,” IBM Technical Disclosure Bulletin, No. 39, No. 1, pp. 167-8, 96A 60059; “Teaching the printing of bar codes on paper to encode data represented by an icon on a computer screen,” IBM Technical Disclosure Bulletin 96A 61092; and “Universal remote control for wide variety of electrical equipment e.g. TV, hi-fi, robot or car navigation unit,” IBM Research Disclosure RD 410,129, which are hereby incorporated by reference.
A watermark can serve the same function as the barcode or other machine readable code in these references. In addition, a watermark can provide additional information about the object as well as machine instructions (e.g., Java applet, Visual Basic Script, etc.) to assist in automating the process of accessing the network resource. In some implementations, the watermark on an object may be used to carry a supplemental, redundant or complimentary message as the bar code.
To illustrate this application, consider the following implementation. The watermarked object containing the embedded object reference is virtually any object, including, for example, a card, piece of paper (e.g., magazine advertisement, mailer, catalog, etc.), a product, etc. Note that the object may also be in an electronic form, such as a piece of software, video, image, audio file, etc. The reader unit is a personal computer equipped with a digital camera or scanner. The computer is linked to other computers on the Internet via standard network communication and telephony equipment.
First, the reader unit captures an image of the watermarked object. For electronic objects, the digital camera and scanner are unnecessary since the reader unit can operate directly on the electronic data, skipping the step of converting it to digital form.
The watermark detector and reader processes described above are implemented in a reader program running in the computer. The reader extracts the object reference, which represents a UID. Acting first as a machine instruction, the UID signals the reader program to invoke an Internet browser such as Internet Explorer from Microsoft Corp, or Navigator from Netscape Communications Corp. In the Windows Operating System, for example, the reader can request the operating system to launch a program by invoking a run command of the operating system and naming the application. The reader passes the UID to the browser along with an instruction to access a remote server on the Internet. The browser issues a request to the server computer to interpret the UID and link the user's computer to a web site that the UID references.
A number of variations to this scenario are possible. For example, the reader can maintain its own database that cross-references the UID to a URL. This approach enables the reader to look up the URL based on the UID and then provide the URL to the browser. Alternatively, the object reference extracted from the watermark could include the URL.
To leverage existing product coding standards, the UID can encode the standard bar code information, such as the information in a UPC symbol. The reader application, or an application running on the server, can then access a database that cross references the UPC symbol with a URL to find the appropriate URL and link to the user's computer to a corresponding web site on the Internet.
In addition to providing a link to a network resource, the object reference may provide, or cause the user's computer to provide, information about the user. This enables the server to gather marketing data about the user. In addition, it allows the web site operator to personalize the web page returned to the user's computer. For example, the web page may tailor a web page about a product to emphasize aspects of it that the user is likely to be interested in.
Retail Point of Sale
As noted above, a watermark on an object can replace or supplement a barcode, such as a UPC symbol or other standard product code, in a retail point of sale application. In this application, the object reference embedded in the watermark on the product packaging labeling, packaging or tag provides a product identifier. The reader unit at the checkout counter extracts the product identifier from the watermark and uses it to look up the product and its price.
If the watermark is encoded on plural surfaces of an object (e.g., all around a box or can), the cashier need not manipulate the object to expose a certain surface to a scanner, as is typically required in the prior art. A reduction in repetitive motion injuries (e.g., RSI) may result.
In the framework depicted in FIG. 10 , the reader unit corresponds to a cash register terminal connected to a digital camera or scanner. The cash register terminal is a computer system with a microprocessor and memory system. It preferably executes a multitasking operating system to support watermark reader, database management and network communication software.
The watermark reader software is preferably integrated with a cash register system that tabulates the total sale, handles various methods of payment (e.g., cash, check, credit card, store credit), and adds tax where applicable. The cash register is equipped with a display monitor that displays various prompts, including information about the product in response to scanning its watermark. The cash register is programmed to perform a variety of other functions, such as tracking layaways and custom order deposits, performing credit checks and alerting cashiers of bad credit history, handle refinds and exchanges, communicate with other computer systems via a network, etc.
In some implementations, the reader unit can also recognize the protocol by which currency may some day be watermarked. In such case, the associated terminal can compute the change due (e.g., from a twenty dollar bill) to the customer, reducing cashier and customer error (e.g., a customer tendering a ten dollar bill, thinking it is a twenty).
Database management software may be used to perform inventory control as items are purchased, returned or reserved. For each of these transactions, in store personnel use a camera or scanner to read the product identifier from the watermarked product. The reader software extracts the product identifier and communicates the identifier along with input identifying the type of the transaction to database management software, which in turn, updates a database that tracks store inventory.
In a similar fashion, watermark labels on shelves may also be used to track the types and number of products on shelves. In the storeroom, watermarks on shipping containers help track when new products have arrived and have been added to the inventory.
In addition to the point of sale functions, the watermark may be used to provide product support after the sale. For example, a watermark on the product or embedded in an object associated with the product, such as an invoice or warranty card can enable the product owner to link to a database to access product or service support information. In one scenario, for instance, the buyer registers the product by using the watermark to link to the seller's computer and provide information about the buyer. Subsequent to the sale, the buyer uses the link to access a database with the product's user instructions and repair information. The seller may enable the user to submit feedback via the link to an interactive web site. Through this link, the seller maintains a history of product, including a repair history. The seller can post product updates and promotions at the interactive web site as well.
Watermark embedding functions may be incorporated into point of sale applications as well. It is useful to encode information about the transaction in a tangible record such as an invoice, receipt, or label affixed to the product. This information can be encoded in a watermark image and printed directly on the transaction record. To simplify the watermark signal, for example, the embedder can encode a transaction identifier that serves as an index to a transaction database entry, which stores information about the transaction. Such information facilitates processing of returns and exchanges. It also allows the vendor to keep a history of a product after the transaction. For instance, if the product needs to be repaired, then the vendor can automatically update a product history database by scanning the transaction record. If the user wants repair information or instructions, the watermark can act as a portal to the vendor's web site as described above.
Watermark messaging provides a number of advantages for retail applications. The watermark may be replicated throughout a substantial portion of the packaging or labeling. If invisible watermarks are employed, the watermark does not detract from the aesthetics of the packaging. Also, it facilitates scanning by store personnel because the user does not have to search for the code or physically position the product or reader in an uncomfortable position.
Object Counting and Tracking
A variety of object counting and tracking applications can be implemented using watermark object identifiers on objects to be counted and tracked. Some example applications include file tracking, specimen tracking, asset tracking, time and attendance tracking, work in process (WIP) tracking, and warranty repair tracking, to name a few. In these applications, the object reference includes an identifier. The reader unit extracts the identifier and records application specific data, such as the time, the number of objects, the location, the weight/volume of the object, monetary data (e.g., object value, cost or price). The reader unit typically operates in conjunction with other software, such as database management software, that gathers data from the reader and other input devices and stores them in data records associated with the objects being tracked. This software may be implemented within the reader unit, or a remote device, as shown in the configuration of FIG. 10 .
Inventory Control
Watermark identifiers on products or their containers can be used to track product inventory. In these applications, the inventory items are marked with an object reference that includes an object identifier. The reader unit operates in conjunction with inventory management software that increments and decrements a database of items as they flow in and out of inventory. Inventory items may be marked by printing a watermark on a label, which is affixed to the item, or by directly applying the watermark to the object surface.
Production Control
Watermark identifiers on objects, including labels, packaging and containers, can be used in production control. For example, the watermark may encode information about the object such as an identifier, a machine instruction or set of instruction, or an index to information or instructions. The reader units are positioned at various points in a production or manufacturing process. As the objects move through production, the reader units read the object reference from the watermark and communicate the information to a local or remote control (see the configuration of FIG. 10 for example). The control device responds by performing manufacturing operations triggered based on the object reference.
Postal Applications
Watermark codes can be used to track and sort many forms of mail. Watermarks provide an advantage relative to some other machine-readable codes in that they can be replicated throughout the object surface and can be scanned from a variety of orientations. Envelopes are particularly suitable for watermarking by texturing.
Operating Environment for Computer Implementations
FIG. 11 illustrates an example of a computer system that serves as an operating environment for object messaging and watermarking applications implemented in a computer and computer network. The computer system includes a computer 520 , including a processing unit 521 , a system memory 522 , and a system bus 523 that interconnects various system components including the system memory to the processing unit 521 .
The system bus may comprise any of several types of bus structures including a memory bus or memory controller, a peripheral bus, and a local bus using a bus architecture such as PCI, VESA, Microchannel (MCA), ISA and EISA, to name a few.
The system memory includes read only memory (ROM) 524 and random access memory (RAM) 525 . A basic input/output system 526 (BIOS), containing the basic routines that help to transfer information between elements within the computer 520 , such as during start-up, is stored in ROM 524 .
The computer 520 further includes a hard disk drive 527 , a magnetic disk drive 528 , e.g., to read from or write to a removable disk 529 , and an optical disk drive 530 , e.g., for reading a CD-ROM disk 531 or to read from or write to other optical media. The hard disk drive 527 , magnetic disk drive 528 , and optical disk drive 530 are connected to the system bus 523 by a hard disk drive interface 532 , a magnetic disk drive interface 533 , and an optical drive interface 534 , respectively. The drives and their associated computer-readable media provide nonvolatile storage of data, data structures, computer-executable instructions (program code such as dynamic link libraries, and executable files), etc. for the computer 520 .
Although the description of computer-readable media above refers to a hard disk, a removable magnetic disk and a CD, it can also include other types of media that are readable by a computer, such as magnetic cassettes, flash memory cards, digital video disks, Bernoulli cartridges, and the like.
A number of program modules may be stored in the drives and RAM 525 , including an operating system 535 , one or more application programs 536 , other program modules 537 , and program data 538 .
A user may enter commands and information into the personal computer 520 through a keyboard 540 and pointing device, such as a mouse 542 . Other input devices may include a microphone, joystick, game pad, satellite dish, digital camera, scanner, or the like. A digital camera or scanner 43 may be used to capture the target image for the detection process described above. The camera and scanner are each connected to the computer via a standard interface 44 . Currently, there are digital cameras designed to interface with a Universal Serial Bus (USB), Peripheral Component Interconnect (PCI), and parallel port interface. Two emerging standard peripheral interfaces for cameras include USB2 and 1394 (also known as firewire and iLink).
These and other input devices are often connected to the processing unit 521 through a serial port interface 546 that is coupled to the system bus, but may be connected by other interfaces, such as a parallel port, game port or a universal serial bus (USB).
A monitor 547 or other type of display device is also connected to the system bus 523 via an interface, such as a video adapter 548 . In addition to the monitor, personal computers typically include other peripheral output devices (not shown), such as speakers and printers.
The computer 520 operates in a networked environment using logical connections to one or more remote computers, such as a remote computer 549 . The remote computer 549 may be a server, a router, a peer device or other common network node, and typically includes many or all of the elements described relative to the computer 520 , although only a memory storage device 550 has been illustrated in FIG. 5 . The logical connections depicted in FIG. 5 include a local area network (LAN) 551 and a wide area network (WAN) 552 . Such networking environments are commonplace in offices, enterprise-wide computer networks, intranets and the Internet.
When used in a LAN networking environment, the computer 520 is connected to the local network 551 through a network interface or adapter 553 . When used in a WAN networking environment, the personal computer 520 typically includes a modem 54 or other means for establishing communications over the wide area network 552 , such as the Internet. The modem 554 , which may be internal or external, is connected to the system bus 523 via the serial port interface 546 .
In a networked environment, program modules depicted relative to the personal computer 520 , or portions of them, may be stored in the remote memory storage device. It will be appreciated that the network connections shown are exemplary and that other means of establishing a communications link between the computers may be used.
Concluding Remarks
Having described and illustrated the principles of the invention with reference to specific implementations, it will be recognized that the principles thereof can be implemented in many other, different, forms. To provide a comprehensive disclosure without unduly lengthening the specification, applicants incorporate by reference the patents and patent applications referenced above.
The particular combinations of elements and features in the above-detailed embodiments are exemplary only; the interchanging and substitution of these teachings with other teachings in this and the incorporated-by-reference patents/applications are also contemplated. | The disclosure relates generally to audio and video signal processing. One claim recites a method comprising: receiving audio or video content, wherein the audio or video content comprises a hidden steganographic code including information, the steganographic code being hidden in the audio or video content through alterations to data representing the audio or video content; detecting the steganographic code to obtain the information, said act of detecting utilizes correlation to obtain the information; providing at least a portion of the information to a data repository to identify machine-executable instructions stored therein; providing data associated with a user to the data repository; receiving machine-executable instructions from the data repository; and executing the machine-executable instructions to control processing of the audio or video content. Of course, other claims and combinations are provided too. | 71,831 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Application Ser. No. 61/699,645, entitled “Adjustable Current Collector Bar and Method of Using the Same” filed on Sep. 11, 2012, which is incorporated by reference in its entirety.
FIELD OF THE INVENTION
Broadly, the present disclosure relates to systems and methods for producing aluminum in electrolytic cells, while simultaneously reducing CVD and/or maintaining a low CVD. More particularly, the instant disclosure relates to utilizing a current collector bar in conjunction an expandable material in an inner void which expands as temperature increases (e.g. during pre-heat and during cell operation) to reduce voltage drop between the collector bar and the cathode (e.g. cathode block) during operation of the electrolysis cell.
BACKGROUND
During conventional aluminum production, electricity is supplied to the electrolytic cell in order to drive the production of aluminum. Voltage is lost in the cell due to inefficiencies in the design, particularly in the electrical contact sites as the electrical current from the cell is transferred out of the system. This loss of voltage is commonly known as cathode voltage drop, or “CVD”. Poor contact caused during the cathode assembly formation, cell start up, and/or through the continued operation of the cell at extreme conditions (e.g. high temperatures) contributes to CVD. The cost of voltage loss from CVD in operating electrolysis cells can add up to millions of dollars per year, per plant.
SUMMARY OF THE DISCLOSURE
Broadly, the present disclosure relates to systems and methods for producing non-ferrous metal (e.g. aluminum) in electrolytic cells, while simultaneously reducing CVD. More particularly, the instant disclosure relates to utilizing an adjustable (expandable) current collector bar in conjunction with an electrolysis cell. In some embodiments, by expanding the inner void of the current collector bar, it is possible to maintain and/or improve the contact (e.g. electrical contact) between various electrolysis cell components (e.g. the cathode collector bar(s) and the cathode). In some embodiments, the expandable current collector bar improves contact between cathode assembly subcomponents, reducing joint electrical resistance (i.e. electrical resistance across the joint of at least two components), thus resulting in a reduction in CVD in the cell.
In one aspect of the instant disclosure, an electrolysis cell is provided, comprising: an anode; at least one cathode block; and a current collector bar configured to be at least partially disposed adjacent to and in electrical communication with the cathode block, wherein the current collector bar comprises: at least one sidewall; an inner void enclosed by the sidewall; and an expandable material retained in the inner void via the at least one sidewall, wherein the expandable material is configured to exert pressure on the wall of the inner void while the collector bar is at operating temperature, such that the collector bar is conformed to the cathode block.
In one aspect of the instant disclosure, a current collector bar is provided, comprising: at least one sidewall which is configured to completely enclose an inner void; and an expandable material retained in the inner void via the at least one sidewall, wherein the expandable material is configured to exert pressure on the wall of the inner void while the collector bar is at a temperature of at least about 200° C., such that the at least one sidewall is deformed via the pressure exerted on the wall of the inner void.
In some embodiments, the adjustable current collector bar promotes contact between the slot of the cathode block and the current collector subassembly (e.g. current collector bar, and in some embodiments, sheath/cover/joint of conductive material). In one embodiment, the current collector bar is configured to impart force (or pressure) onto the cathode (e.g. slot).
In one embodiment, as the collector bar pressurizes, it presses/conforms against the cathode (e.g. in an transverse direction), as it expands in a transverse direction, against, and into contact with the surface of the slot. In one embodiment, as the bar expands transversely, it conforms itself to the surface of the slot. Thus, in some embodiments, the bar increases the surface area of contact (and reduces the electrical resistance) across the current collector subassembly (i.e. between itself and the slot of the cathode block). In one embodiment, as the amount of shared surface area between the block and bar increases, the electrical resistance at the joint decreases. Thus, in some embodiments, the adjustable (pressurizable) current collector bar reduces CVD in the electrolysis cell.
Joint resistance in the cathode assembly may be attributed to one or more mechanisms and/or sources. Some non-limiting examples of sources of joint resistance in the cathode assembly include: creep, phase change, spacer standoff, voids, non-conforming surfaces, and combinations thereof. In various embodiments, voids, phase changes, and creep occur respectively before, during, and after the startup of a pot (cell). In some embodiments, a resulting surface non-conformity between the bar and slot has components that develop in each of these phases. The instant disclosure prevents, reduces and/or eliminates joint resistivity (i.e. high electrical resistance) by utilizing an adjustable cathode collector bar (e.g. pressurizable) to apply stress to the components of the cathode assembly, thus conforming the cathode collector bar subassembly. In some embodiments, the bar applies stress to the cathode slot while the cell is cold, during start up, or at operating conditions (e.g. high temperature and pressure) and promotes bar deformation (e.g. creep) to the cathode block slot in a way that the joint mechanical conformity and electrical connection is improved during operation of the cell at operating conditions (e.g. elevated temperatures).
In some embodiments, the inner void expands and imparts pressure on the current collector bar, which expands/compresses into the slot (e.g. imparts force) on the current collector subassembly when: (1) the cell is idle; (2) during start-up; (3) during operating conditions, and/or (4) combinations thereof. In one or more of these embodiments, the adjustable collector bar imparts a continuous amount of force on the cathode. In one or more embodiments, the bar imparts a variable amount of force on the cathode (e.g. based on a feedback loop). Thus, in one or more embodiments, the collector bar: prevents an increase in CVD, reduces CVD, and/or maintains low levels of CVD across a cathode assembly. In some embodiments, the joint's contribution to CVD (i.e. the cathode collector subassembly/cathode slot joint) is eliminated.
In one embodiment, the expandable material therein selected from the group consisting of: a gas, an inert gas, a phase change material, MgCO 3 , CaCO 3 , Na 2 CO 3 , carbonates, sulfates, a degrading material, a decomposing material and combinations thereof.
In some embodiments, the expandable material expands at a temperature of: at least about 100° C.; at least about 150° C.; at least about 200° C.; at least about 250° C.; at least about 300° C.; at least about 350° C.; at least about 400° C.; at least about 500° C.; at least about 550° C.; at least about 600° C.; at least about 650° C.; at least about 700° C.; at least about 750° C.; at least about 800° C.; at least about 850° C.; at least about 900° C.; at least about 950° C.; at least about 1000° C.; or greater.
In some embodiments, the expandable material expands at a temperature of: not greater than about 100° C.; not greater than about 150° C.; not greater than about 200° C.; not greater than about 250° C.; not greater than about 300° C.; not greater than about 350° C.; not greater than about 400° C.; not greater than about 500° C.; not greater than about 550° C.; not greater than about 600° C.; not greater than about 650° C.; not greater than about 700° C.; not greater than about 750° C.; not greater than about 800° C.; not greater than about 850° C.; not greater than about 900° C.; not greater than about 950° C.; not greater than about 1000° C.; or greater.
In one embodiment, the expandable material undergoes a phase change at a temperature exceeding about 100° C. In one embodiment, the expandable material undergoes a volumetric expansion as approximately described by the ideal gas law.
In some embodiments, the expandable material comprises: a gas. In some embodiments, the expandable material comprises a gas which evolves from a solid material. In some embodiments, the collector bar further comprises a container which is configured to retain a gas and release said gas at a predetermined temperature. In some embodiments, the container houses a pressurized gas, which is released when the container reaches a certain temperature (e.g. container melts or container has a vent built in which releases the gas once the pressure reaches a certain predetermined level.)
In some embodiments, the expandable material is configured to expand during heat-up of the cell. In some embodiments, the expandable material is configured to expand during operation of the cell. In some embodiments, the internal pressure of the collector bar is increased by the expansion of the expandable material in the inner void. In some embodiments, the internal pressure of the collector bar is maintained by the seal of the collector bar. In some embodiments, the pressure of the inner cavity of the collector bar is increased by about a factor of 5 during preheat. In some embodiments, the pressure of the inner cavity of the collector bar is increased by about a factor of 5 during operation of the cell. In some embodiments, the inner void is sealed by the at least one sidewall so that the gas retained in the inner void does not escape from the collector bar. In some embodiments, the collector bar does not have a vent. In some embodiments, the collector bar is not opened to the atmosphere to vent and/or reduce pressure inside the system.
In some embodiments the pressure increase in the inner void of the collector bar is maintained even with subsequent expansion and/or deformation of the collector bar.
In one embodiment the void comprises a filler material (e.g. which is non-reactive and which does not undergo an expansion).
In some embodiments, the void comprises a conductive material. In some embodiments, the conductive material comprises a greater electrical conductivity than the at least one sidewall (e.g. copper and copper alloys). In some embodiments, the conductive material comprises a bar, a plate, a rod, a pipe (e.g. with a central via), a plurality of tabs, a plurality of shot material, and combinations thereof.
In one embodiment, the cell includes an anchor in communication with and end of the current collector bar, where the anchor is configured to limit movement of the current collector bar in a longitudinal direction (e.g. out of the cell). In some embodiments, the anchor comprises a rigid support which includes a mechanical fastener (e.g. bolt) which retains the collector bar in position (i.e. before the expandable material increases the pressure on the wall of the inner void). In some embodiments, the anchor comprises a stepped configuration of the cathode collector bar, which, with cooperation with the outer shell, anchors the collector bar in position in the cathode collector subassembly.
In one embodiment, the expandable materials are configured to increase the pressure in the inner void by at least about 50 psig at cell operating conditions.
In one embodiment, the inner void comprises a pressure of at least about 15 PSIG at a temperature of 20-25° C. (e.g. pre-pressurized).
In one embodiment, the adjustable current collector bar reduces the cathode voltage drop between the cathode and the current collector bar by at least about 50 mV.
In one embodiment, the transverse cross-sectional area percentage of the inner void to the collector bar is at least about 10%. In one embodiment, the transverse cross-sectional area percentage of the inner void to the collector bar is not greater than about 90%.
In one embodiment, the pressure in the inner void exerts force on the sidewall of the bar. In one embodiment, the current collector bar imparts force onto the at least one sidewall of the bar to transversely expand the sidewalls against the cathode block, maintaining the interface between the current collector bar and the cathode block.
In one embodiment, the collector bar further comprises: a joint material composed of a conductive material, located between and in electrical communication with the cathode and the current collector bar. In some embodiments, the joint material comprises copper. In some embodiments, the joint material comprises cast iron. In some embodiments, the joint material comprises paste (e.g. conductive material).
In one embodiment, the apparatus further comprises: an expansion detector in communication with the adjustable conductor bar and configured to measure the expansion of the bar.
In another aspect of the instant disclosure, a method is provided. The method of making a primary metal (e.g. aluminum) comprises: (a) transmitting an electrical current from an anode to a cathode assembly, via a liquid medium at a temperature of at least about 800° C., wherein the cathode assembly comprises: a cathode block, in electrical communication with at least one of the liquid medium and a metal pad (produced via electrolysis) and an adjustable current collector bar, adjacent to and in electrical communication with the cathode, the adjustable current collector bar comprising: at least one sidewall enclosing an inner void having an expandable material therein, wherein the expandable material is configured to expand at a temperature exceeding about 800° C.; (b) transversely expanding the sidewall of the current collector bar, via an increase in pressure of the inner void, due to the expansion of the expandable material, and c) maintaining, due to the expansion step, contact between the slot of the cathode block and the current collector subassembly.
In one embodiment, the expanding/conforming step (e.g. compressing the sidewall of the current collector bar into the slot or interface of the cathode block) is sufficient to effect a reduction in a cathode voltage drop across the cathode assembly of at least about 50 mV.
In one embodiment, the expanding/conforming step further comprises: conforming the current collector bar to the cathode to reduce the electrical resistance.
In one embodiment, the expanding/conforming step further comprises conforming the current collector subassembly to the cathode block to reduce the cathode voltage drop (CVD) from about 10 mV to about 100 mV.
In one embodiment, the method further includes the step of: determining the force imparted by the current collector bar via the expansion detector (sensor).
In some embodiments, the bar includes an inner void with an expandable material. In one embodiment, in order to impart force, the adjustable bar is pressurized into place into a cathode (e.g. at the slot). In some embodiments, the at least one sidewall of the bar is conformed to the cathode based on the based upon the pressure inside the bar and/or the temperature of the bar/cell components. In one embodiment, the adjustable bar is a metal material (e.g. metallic). In some embodiments, the bar is: a carbon steel, a ferritic/magnetic material, and combinations thereof. Non-limiting examples of the aforementioned materials include: 430, 410, and 409. Some non-limiting examples of bar materials include: carbon steel, stainless steel (e.g. 304, 304L), and steel. In one embodiment, the bar includes at least one wall that seals in an inner void. In various embodiments, the bar is of different shapes, including rectangular, oval, circular, and the like. As some non-limiting examples, the dimension of the bar includes: a rectangular shape, a square shape, a polygonal shape, an oval shape, and/or a rounded shape. In some embodiments, the bar comprises corners. In some embodiments, the bar comprises rounded edges.
In one aspect of the instant disclosure, an aluminum electrolysis cell is provided. The aluminum electrolysis cell, comprises: an anode (an anode configured to provide an electrical current to the electrolysis cell); a cathode (configured to receive the electrical current); and an adjustable current collector bar is at least partially disposed adjacent to and in electrical communication with the cathode, wherein the adjustable current collector bar comprises: at least one sidewall, an inner void enclosed by the sidewall, and an expandable material retained in the inner void via the at least one sidewall, wherein the expandable material is configured to expand during heat up of the cell (e.g. at cell operating conditions of at least about 800° C.) such that the internal pressure of the inner void increases by a factor of about 5 to exert a compressive force onto the at least one sidewall of the collector bar, to conform (e.g. transversely expand) the collector bar to the cathode. In some embodiments, the sidewall comprises a conductive material. In some embodiments, the sidewall comprises steel, cast iron, carbon, or the like.
In yet another aspect of the invention, a method of making an adjustable bar is provided. The method comprises: forming at least one sidewall around an inner void to provide a metallic body having an opening; inserting an expandable material into the void via the opening (e.g. pre-pressurized void with gas); closing the metallic body, thus completely enclosing the void having an expandable material therein.
In another aspect, a method of making an expandable member is provided. The method comprises: aligning a plurality of (at least two) metallic walls to provide a void therein; and sealing the plurality of walls.
In one embodiment, the bar is cast from a mold. In one embodiment, the bar is extruded to form. In one embodiment, the bar is machined. In one embodiment, the bar is rolled. In one embodiment, the bar portions (e.g. sides) are adhered together. In one embodiment, the bar is welded together (e.g. to retain the material). In one embodiment, the bar is screwed together (e.g. to retain the material). In one embodiment, the bar is bolted together (e.g. to retain the material). In one embodiment, the expandable member is mechanically fastened together (e.g. to retain the material).
In one embodiment, the method comprises inserting a material (e.g. gas, expandable material, filler material) into the void (sometimes called an inner void or central region).
In one embodiment, closing includes sealing the bar with material in the inner void.
In some non-limiting embodiments, sealing includes: welding, mechanically fastening, adhering, riveting, bolting, screwing, and the like.
In some embodiments, the wall of the bar is thick enough to be capable of efficiently removing current from the cell (i.e. transport current from the cathode and/or metal pad to the electrical bus work).
In some embodiments, the wall of the bar is thin enough to be capable of deforming to conform to the cathode (e.g. as the bar is pressurized and/or increases in temperature to operating conditions of at least about 850° C.).
In one embodiment, the percentage of the transverse cross-sectional area of the void to the total bar (bar body plus void) is: at least about 10%; at least about 15%; at least about 20%; at least about 25%; at least about 30%; at least about 35%, at least about 40%; at least about 45%; at least about 50%; at least about 55%; at least about 60%; at least about 65%; at least about 70%; at least about 75%; at least about 80%; at least about 85%; or up to 90%.
In one embodiment, the percentage of the transverse cross-sectional area of the void to the total bar (bar body plus void) is: not greater than about 10%; not greater than about 15%; not greater than about 20%; not greater than about 25%; not greater than about 30%; not greater than about 35%, not greater than about 40%; not greater than about 45%; not greater than about 50%; not greater than about 55%; not greater than about 60%; not greater than about 65%; not greater than about 70%; not greater than about 75%; not greater than about 80%; not greater than about 85%; or up to 90%.
In some embodiments, the thickness of the wall(s) varies. In some embodiments, the wall thickness is continuous throughout. In some embodiments, the wall is: at least about 1/16″ thick; at least about ⅛″ thick; at least about ¼″ thick; at least about ½″ thick; at least about ¾“thick; at least about 1” thick; at least about 1.5″ thick; at least about 2″ thick; at least about 2.5″ thick; or at least about 3″ thick.
In some embodiments, the wall is: not greater than about 1/16″ thick; not greater than about ⅛″ thick; not greater than about ¼″ thick; not greater than about ½″ thick; not greater than about ¾″ thick; not greater than about 1″ thick; not greater than 1.5″ thick; not greater than 2″ thick; not greater than 2.5″ thick; or not greater than 3″ thick.
In some embodiments, the cross-section of the inner void within the bar is square. In some embodiments, the cross-section of the inner void within the bar is rectangular. In some embodiments, the cross-section of the inner void within the bar is I-shaped. In some embodiments, the cross-section of the inner void within the bar is T-shaped.
In some embodiments, the void is filled with air (e.g. of atmospheric composition). In some embodiments, the void comprises a gas (e.g. pure or mixed composition). In some embodiments, the void comprises a filler material (e.g. non-reactive at elevated temperatures (e.g. above 100° C.). In some embodiments, the filler material is a solid non-reactive material which does not expand significantly (e.g. substantially inert) at temperatures exceeding about 100° C. In some embodiments, the void comprises gas at a pressure (e.g. above atmospheric pressure). In some embodiments, the void comprises combinations of at least two of: air (e.g. of atmospheric composition), a gas (e.g. pure or mixed composition), an expandable material, and/or an inert material (i.e. filler material). In some embodiments, the void comprises gas at a pressure (e.g. above atmospheric pressure). In some embodiments, the void comprises an expandable material. In some embodiments, the void comprises combinations thereof.
In some embodiments, the inner void takes up a portion of the volume of the bar. In some embodiments, the inner void is: at least about 5% by vol.; at least about 10% by vol.; at least about 15% by vol.; at least about 20% by vol.; at least about 25% by vol.; at least about 30% by vol.; at least about 35% by vol.; at least about 40% by vol.; at least about 45% by vol.; at least about 50% by vol.; at least about 55% by vol.; at least about 60% by vol.; at least about 65% by vol.; at least about 80% by vol.; at least about 85% by vol.; at least about 90% by vol.; at least about 95% by vol.; or at least about 98% by volume of the bar.
In some embodiments, the inner void is: not greater than about 5% by vol.; not greater than about 10% by vol.; not greater than about 15% by vol.; not greater than about 20% by vol.; not greater than about 25% by vol.; not greater than about 30% by vol.; not greater than about 35% by vol.; not greater than about 40% by vol.; not greater than about 45% by vol.; not greater than about 50% by vol.; not greater than about 55% by vol.; not greater than about 60% by vol.; not greater than about 65% by vol.; not greater than about 80% by vol.; not greater than about 85% by vol.; not greater than about 90% by vol.; not greater than about 95% by vol.; or not greater than about 98% by volume of the bar.
As used herein, adjustable bar refers to an object that expands or enlarges under different conditions (e.g. adjusts). As non-limiting examples, the expansion and/or increase in pressure is attributable to phase change, decomposition, and/or density change upon different temperature or pressure conditions. In one non-limiting example, the bar's internal pressure increases at increased temperature. As another example, at the increased temperature, the inner expandable material undergoes a phase change (i.e. solid to gas) to increase volume at the increased temperature.
In some embodiments, gas (air) having an atmospheric composition is present inside the bar and upon temperature elevation; at least some oxygen (O 2 ) present in the air is removed from the system (e.g. rusts) so that the pressure inside the void at elevated temperature (e.g. 900° C.) is about 3.2 ATM. In some embodiments, the pressure inside the bar (e.g. in the void) drops as the bar expands, so in these embodiments, the expandable material is selected in order to create the appropriate amount of material expansion (e.g. pressure increase) to drive creep. In some embodiments, there is a reduction in the inner pressure due to loss of oxygen (e.g. surface reactions with the bar, like rust) and subsequent volume increase of the bar (e.g. metal expansion).
Non-limiting examples of expandable materials include: MgCO 3 (decomposes at 350° C.); CaCO 3 (Calcite, decomposes at 898° C.), or CaCO 3 (aragonite, decomposes at 825° C., where each of these materials releases carbon dioxide gas at elevated temperatures, and which might be used separately or in combination. Other non-limiting examples of expandable materials include any chemical that degrades at elevated temperatures; for example, temperatures exceeding about 800° C. (e.g. cell operating temperature, at least about 900° C., or at least about 930° C.).
In some embodiments, the expandable material is a pressurized gas, in a secondary container inserted in the bar during assembly. In some embodiments, the secondary container is configured or adapted to melt, and/or leak (e.g. at elevated temperatures of at least about 100° C.), releasing the pressurized gas into the cavity inside the bar.
In some embodiments, at elevated temperature and pressure conditions inside the bar, the gas and/or expandable material inside the bar expand to pressure the bar and push the walls outward. In some embodiments, the rise from ambient temperature to cell operating temperature (e.g. 900° C.-930° C.) increases the internal absolute pressure by a factor of 4 inside the bar.
In another embodiment, a filler material (e.g. inert material) is used inside the bar. In one embodiment, the filler material is porous and/or particulate. As non-limiting examples, the filler material includes tabular alumina, gravel, aggregate, ceramic materials, and the like, which fill a portion of, or the entirety of, the cavity. In some embodiments, by utilizing a filler material, the size of the cavity could be large, while the amount of gas providing the pressure (i.e. the volume that is not occupied by inert material) would be small. With such an embodiment, it is possible to limit creep in the bar, (which would slow as the cavity expanded and pressure dropped). Also, with such an embodiment, the amount of gas that could potentially erupt from the bar during the pot operation is reduced, as compared to an embodiment in which the entire void was filled with gas.
In some embodiments, the improved contact at the interface of the slot and the bar is measureable, correlated, and/or quantified by one or more characteristics. As non-limiting examples, the bar causes a decrease in electrical resistance, an increase in surface area (between the cathode block slot and the cathode current subassembly, a dimensional change in the current collector subassembly (e.g. the amount of collector bar that extends from the cell), and combinations thereof.
When measuring the improved contact by a decreased electrical resistance, the resulting interface comprises a common surface area sufficient to reduce a measured cathode voltage drop in the electrolysis cell by a measureable amount.
In some embodiments, the resulting, improved contact at the interface comprises a common surface area sufficient to reduce a measured cathode voltage drop (e.g. across the cathode assembly) by: at least about 10 mV; at least about 20 mV; at least about 30 mV; at least about 40 mV; at least about 50 mV; at least about 60 mV; at least about 70 mV; at least about 80 mV; at least about 90 mV; 100 mV; at least about 120 mV; at least about 140 mV; or at least about 160 mV.
In some embodiments, the resulting, improved contact at the interface comprises a common surface area sufficient to reduce a measured cathode voltage drop (e.g. across the cathode assembly) by: not greater than about 10 mV; not greater than about 20 mV; not greater than about 30 mV; not greater than about 40 mV; not greater than about 50 mV; not greater than about 60 mV; not greater than about 70 mV; not greater than about 80 mV; not greater than about 90 mV; 100 mV; not greater than about 120 mV; not greater than about 140 mV; or not greater than about 160 mV.
In some embodiments, the electrical resistance at the joint is reduced by a factor of: at least about 3; at least about 5; at least about 10; at least about 20; at least about 40; at least about 60; at least about 80; or at least about 100.
In some embodiments, the electrical resistance at the joint is reduced by a factor of: not greater than about 3; not greater than about 5; not greater than about 10; not greater than about 20; not greater than about 40; not greater than about 60; not greater than about 80; or not greater than about 100.
In some embodiments, when measuring the improved contact by an increased surface area at the joint or interface between the cathode block and the current collector subassembly (or alternatively, joint material/cathode block slot), the improvement is measured as an increase in surface area. This is generally depicted, by comparing: (a) FIG. 8A with FIG. 8B , (b) FIG. 9A with FIG. 9B ; (c) FIG. 10A with FIG. 10B ; and/or (d) FIG. 10C with FIG. 10D .
In some embodiments, the bar increases the amount of contact (or common surface area) by: at least about 2%; at least about 4%; at least about 6%; at least about 8%; at least about 10%; at least about 15%; at least about 20%; at least about 40%; at least about 50%; at least about 75%; or at least about 100% (e.g. when no contact existed before the bar was pressurized and/or expanded to confirm to the slot.
In some embodiments, the bar increases the amount of contact (or common surface area) by: not greater than about 2%; not greater than about 4%; not greater than about 6%; not greater than about 8%; not greater than about 10%; not greater than about 15%; not greater than about 20%; not greater than about 40%; not greater than about 50%; not greater than about 75%; or not greater than about 100%.
In some embodiments, when measuring the improved contact by a dimensional change in the current collector bar while the bar is under stress, the improved contact at the interface between the cathode block and the current collector bar is measured by the difference in dimension and/or length (e.g. along a longitudinal direction) of the collector bar as it protrudes from the wall of the electrolysis cell.
In some embodiments, as the bar is compressed longitudinally, the bar expands (i.e. increases) in width or height or both (e.g. along a transverse direction) to align in better contact with the surface area of the slot. In some embodiments, the bar exhibits a decrease in length along a longitudinal direction and an increase in width along a transverse direction.
In some embodiments, the improvement in electrical contact refers to an increase in the transverse dimension by: at least about 0.1%; at least about 0.3%; at least about 0.5%; at least about 0.7%; at least about 1%; at least about 1.1%; at least about 1.3%; at least about 1.5%; at least about 1.7%; at least about 2%; or at least about 2.5%.
In some embodiments, the improvement in electrical contact refers to an increase in the transverse dimension by: not greater than about 0.1%; not greater than about 0.3%; not greater than about 0.5%; not greater than about 0.7%; not greater than about 1%; not greater than about 1.1%; not greater than about 1.3%; not greater than about 1.5%; not greater than about 1.7%; not greater than about 2%; or not greater than about 2.5%.
In one embodiment, the improved contact at the interface is measured by a dimensional change of the bar under stress by not greater than 10% in a longitudinal direction (i.e. length) and not greater than 5% in a transverse direction (i.e. width).
In some embodiments, the inner void imparts pressure on the bar, resulting in compressive stress of the at least one sidewall of the bar into/onto the cathode block in various amounts, including: at least about 50 psi; at least about 100 psi; at least about 150 psi; at least about 200 psi; at least about 250 psi; or at least about 300 psi.
In some embodiments, the inner void of the bar expands to compress the sidewall of the bar onto the surface of the cathode block (e.g. slot) in various amounts, including: not greater than about 50 psi; not greater than about 100 psi; not greater than about 150 psi; not greater than about 200 psi; not greater than about 250 psi; or not greater than 300 psi.
In some embodiments, the amount of force applied by the bar to the cathode is large enough for the prevention, reduction, or elimination of gaps between the current collector bar and the cathode block. In some embodiments, by eliminating, reducing, and/or preventing the gap, the adjustable current collector bar reduces CVD across the aluminum electrolysis cell and increases efficient removal of electric current from the system.
In some embodiments, the bar imparts a resulting strain in a longitudinal axial direction of: at least about −0.01%; at least about −0.02%; at least about −0.03%; at least about −0.04%/at least about −0.05%; at least about −0.06%; at least about −0.07%; at least about −0.08%; at least about −0.09%; at least about −0.1%. In some embodiments, the bar imparts a strain in the longitudinal (axial) direction of: at least about −0.1%; at least about −0.15%; at least about −0.2%; at least about −0.25%; at least about −0.3%; at least about −0.35%; at least about −0.4%; at least about −0.45%; at least about −0.5%; at least about −0.55%; at least about −0.6%; at least about −0.65%; at least about −0.7%; at least about −0.75%; at least about −0.8%; at least about −0.85%; at least about −0.9%; at least about −0.95%; or at least about −1%.
In some embodiments, the bar imparts a resulting strain in a longitudinal (axial) direction of: not greater than about −0.01%; not greater than about −0.02%; not greater than about −0.03%; not greater than about −0.04%/not greater than about −0.05%; not greater than about −0.06%; not greater than about −0.07%; not greater than about −0.08%; not greater than about −0.09%; not greater than about −0.1%. In some embodiments, the bar imparts a strain in the longitudinal (axial) direction of: not greater than about −0.1%; not greater than about −0.15%; not greater than about −0.2%; not greater than about −0.25%; not greater than about −0.3%; not greater than about −0.35%; not greater than about −0.4%; not greater than about −0.45%; not greater than about −0.5%; not greater than about −0.55%; not greater than about −0.6%; not greater than about −0.65%; not greater than about −0.7%; not greater than about −0.75%; not greater than about −0.8%; not greater than about −0.85%; not greater than about −0.9%; not greater than about −0.95%; or not greater than about −1%.
In some embodiments, the bar imparts a resulting strain in a transverse direction of: at least about 0.01%; at least about 0.02%; at least about 0.03%; at least about 0.04%/at least about 0.05%; at least about 0.06%; at least about 0.07%; at least about 0.08%; at least about 0.09%; at least about 0.1%. In some embodiments, the bar imparts a strain in the transverse direction of: at least about 0.1%; at least about 0.15%; at least about 0.2%; at least about 0.25%; at least about 0.3%; at least about 0.35%; at least about 0.4%; at least about 0.45%; at least about 0.5%; at least about 0.55%; at least about 0.6%; at least about 0.65%; at least about 0.7%; at least about 0.75%; at least about 0.8%; at least about 0.85%; at least about 0.9%; at least about 0.95%; or at least about 1%.
In some embodiments, the bar imparts a resulting strain on in a transverse direction of: not greater than about 0.01%; not greater than about 0.02%; not greater than about 0.03%; not greater than about 0.04%; not greater than about 0.05%; not greater than about 0.06%; not greater than about 0.07%; not greater than about 0.08%; not greater than about 0.09%; not greater than about 0.1%. In some embodiments, the bar imparts a strain in the transverse direction of: not greater than about 0.1%; not greater than about 0.15%; not greater than about 0.2%; not greater than about 0.25%; not greater than about 0.3%; not greater than about 0.35%; not greater than about 0.4%; not greater than about 0.45%; not greater than about 0.5%; not greater than about 0.55%; not greater than about 0.6%; not greater than about 0.65%; not greater than about 0.7%; not greater than about 0.75%; not greater than about 0.8%; not greater than about 0.85%; not greater than about 0.9%; not greater than about 0.95%; or not greater than about 1%.
In one aspect of the instant disclosure, an aluminum electrolysis cell is provided. The aluminum electrolysis cell includes: an anode; a cathode assembly; a liquid medium (e.g. molten salt bath. In one embodiment, the cathode assembly includes: a cathode block having a slot and a current collector subassembly. In one embodiment, the current collector subassembly is at least partially disposed in the slot of the cathode block. In some embodiments, the current collector subassembly is an adjustable bar, or an adjustable bar with a joint material which at least partially wraps (e.g. covers) the bar. In some embodiments, the bar is configured to conform to the cathode via an expansion of material inside the bar. As such, the interface between the current collector subassembly and the cathode block at the slot is maintained by the bar.
In some embodiments, the liquid medium is located between the anode and the cathode assembly. Aluminum is produced in the cell from the liquid medium (also referred to as a molten material/electrolytic bath). In some embodiments, aluminum metal is produced at the interface between the liquid bath and the liquid metal and as it forms, the liquid aluminum accumulates on top of the cathode block.
In one embodiment, the cathode collector subassembly and/or adjustable bar includes a compression detector (e.g. displacement detector). In some embodiments, the detector is located between the cathode block and the bar and the detector is configured to measure the expansion of the bar. In some embodiments, the detector is configured to measure the mechanical interface between the bar and block (e.g. amount of conformation/compression). In some embodiments, the detector is configured to measure the transverse expansion (e.g. fattening) of the bar. In some embodiments, the detector is configured to measure the amount of longitudinal expansion (lengthening) of the bar. In some embodiments, the detector measurements feed into a cell operating system (not shown) for example, as a real-time feedback loop to vary the amount of compression. In some embodiments, the compression is correlated based on the measured cell temperature, which affects the rate of deformation possible in the bar (i.e. through creep).
In another aspect of the instant disclosure, methods of making aluminum are provided. In one embodiment, the method of making aluminum includes the steps of: (a) producing aluminum in an aluminum electrolysis cell; (b) conforming an adjustable current collector bar to a cathode via an expandable material retained in the collector bar; and (c) maintaining, due to the imparting force step, an improved contact between the slot of the cathode block and the current collector subassembly.
In some embodiments, the producing step refers to transmitting electrical current from an anode to a cathode assembly, via a liquid medium, to produce aluminum in the cell. In one embodiment, the method includes: conforming the current collector subassembly to the cathode block to reduce the cathode voltage drop (CVD) by about 10 mV to about 100 mV. In one embodiment, the method includes: transversely expanding the current collector bar, via the conforming step, to maintain and/or improve the electrical contact between the current collector bar and the cathode (e.g. cathode slot). In some embodiments, the resulting electrical resistance from the bar is less than an initial electrical resistance (i.e. as measured without force from the expanded bar). In one embodiment, the method includes adjusting the amount of imparted force (e.g. pressure) to increase, decrease, or maintain the compression of the current collector bar into the cathode block slot at variable or continuous maintained conditions. In one embodiment, the method includes determining the force imparted on the end of the current collector subassembly.
In one embodiment, the inner void (sometimes called cavity) of the collector bar comprises an expandable material that is a gas. In one embodiment, the inner void of the collector bar comprises an expandable material that is a gas and a conductive insert in the collector bar. In one embodiment, the inner void of the collector bar comprises an expandable material that is a gas, a conductive insert, and a filler material.
In one embodiment, the inner void of the collector bar comprises an expandable material that is a pre-pressurized gas (e.g. pressure inside the cavity is above ambient pressure before the cell is pre-heated/before operation). In one embodiment, the inner void of the collector bar comprises an expandable material that is a pre-pressurized gas and a conductive insert into the collector bar. In one embodiment, the inner void of the collector bar comprises an expandable material that is a pre-pressurized gas, a conductive insert, and a filler material.
In some embodiments, the inner void comprises an expandable material that is a phase change material. In some embodiments, the inner void comprises an expandable material that is a phase change material and a conductive insert. In one embodiment, the inner void of the collector bar comprises an expandable material that is a phase change, a conductive insert, and a filler material.
In some embodiments, the inner void comprises at least two different expandable materials (e.g. a gas and a phase change material). In some embodiments, the inner void comprises two different expandable materials and a conductive insert. In some embodiments, the inner void comprises two different expandable materials, a conductive insert, and a filler material.
In one or more of the aforementioned embodiments, the inner cavity is sealed so that gas does not escape the collector bar. In one or more of the aforementioned embodiments, the collector bar does not have a vent. In one or more of the aforementioned embodiments, the sidewall is sealed to completely surround and encase the inner void which includes the expandable material.
In some embodiments, the expandable material is configured to reduce the cathode voltage drop attributed to the joint resistivity (i.e. between the cathode and the current collector bar). In some embodiments, the conductive insert is configured to reduce electrical resistance and/or increase axial conductivity (i.e. as the current leaves the cell).
In some embodiments, the pressure exerted by the expandable material on the wall of the inner void is sufficient to deform the cathode collector bar. In some embodiments, the wall thickness along the at least one sidewall is varied such that the deformation is tailored to the desired surface (i.e. along the collector bar to cathode block interface).
These and other aspects, advantages, and novel features of the technology are set forth in part in the description that follows and will become apparent to those skilled in the art upon examination of the following description and Figures, or is learned by practicing the embodiments of the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic, cross-sectional side view of an embodiment of an aluminum electrolysis cell with an adjustable current collector bar, in accordance with the instant disclosure.
FIG. 2 depicts an embodiment of an adjustable collector bar with the void including an expandable material (e.g. gas), in accordance with the instant disclosure.
FIG. 3 depicts another embodiment of an adjustable collector bar with the void including an expandable material (e.g. gas) and a filler material in accordance with the instant disclosure.
FIG. 4 depicts yet another embodiment of an adjustable collector bar with the void including two types of expandable materials (e.g. gas and a solid material), in accordance with the instant disclosure.
FIG. 5 depicts still embodiment of an adjustable collector bar with the void including an expandable material (e.g. solid), in accordance with the instant disclosure.
FIG. 6 depicts still another embodiment of an adjustable collector bar with the void including an expandable material (e.g. solid) and a filler material, in accordance with the instant disclosure.
FIG. 7 depicts still yet another embodiment of an adjustable collector bar with the void including two types of expandable material (e.g. a gas and a solid) and filler material, in accordance with the instant disclosure.
FIG. 8 depicts still yet another embodiment of an adjustable collector bar with the void including an expandable material (e.g. solid) and a conductive material, in accordance with the instant disclosure.
FIG. 9 depicts still yet another embodiment depicts still yet another embodiment of an adjustable collector bar with the void including an expandable material (e.g. solid), a filler material, and a conductive material, in accordance with the instant disclosure.
FIG. 10 depicts still yet another embodiment of an adjustable collector bar with the void including an expandable material (e.g. solid) and a conductive material surrounding a portion of the solid material, in accordance with the instant disclosure.
FIG. 11 depicts still yet another embodiment of an adjustable collector bar with the void having two zones, a zone including an expandable material (e.g. solid) and filler material and a zone having a expandable material (e.g. solid) and a conductive material, in accordance with the instant disclosure.
FIG. 12A-12E depict various configurations of the adjustable current collector bar, in accordance with the instant disclosure.
FIGS. 13A and 13B depict a side-by-side cut-away view of the slot of the cathode assembly “before” at least one bar (on the left), compared to “after” the bar adjusts/expands (on the right), where FIGS. 13A and 13B depict the conformation of the cathode collector bar to the cathode slot, (thus, the resulting increase in electrical contact of the cell components.).
FIGS. 14A and 14B depict cut-away side views of the contact site between the cathode assembly components at operating conditions: before the bar is adjusted/expanded to impart force on the cathode ( FIG. 14A ), and after the bar is adjusted/expanded ( FIG. 14B ) imparts force on the cathode, in accordance with the instant disclosure. In FIG. 14B , the arrows inside the current collector bar depict the direction of the transverse movement of the bar sides resulting from creep due to the pressure (or force) exerted by the inner void of the bar via the expandable material.
FIGS. 15A-15D depict additional embodiments of types of gaps between the cathode slot and the current collector bars, before and after, the bar is adjusted/expanded. Each of the Figures depicts a close-up view of a portion of the interface (e.g. border) between the cathode block/cathode slot and the current collector bar. FIGS. 15A and 15B depict embodiments of closing of larger macroscopic gaps (e.g. large enough gaps to be visually observable) between the block and the bar, while FIGS. 15C and 15D depict the improvement in contact between smaller scale asperities on the surfaces (e.g. slight projections on the surfaces, like those from surface roughness or unevenness). FIGS. 15A and 15C depict the block and bar interface before the expandable bar is utilized, while FIGS. 15B and 15D depict the block and bar interface after the bar has expanded transversely to increase the surface area of contact.
FIG. 16 depicts a partial cross-sectional vie of an aluminum electrolysis cell showing via arrows, the general flow/path of electrical current through certain cell components.
FIG. 17 depicts the voltage drop of different cell components (carbon cathode block, joint between cathode and collector subassembly, the portion of the collector bar adjacent to (e.g. embedded in) the carbon cathode block (bar in) and the outer end of the collector bar extending outside the carbon cathode block to where the electrical bus work removes current from the cell (bar out). The horizontal axes represent changes between pot lines at various smelters.
FIG. 18 is a graphical depiction of how the stress required for creep in the solid collector bar decreases with increasing temperature, extrapolated to pot operating temperature. The stress required to cause 1% creep over one year (Stress (MPa)) is plotted vs. Temperature (C).
FIG. 19A depicts the differences in thermal expansion of different cathode and collector bar components, plotted as expansion (%) vs. Temperature (C).
FIG. 19B depicts an example of calculated interference that results between the cathode (cath. block) and the collector bar (iron & steel) plotted as Distance (mm) vs. Temp. (C). Negative values represent a gap.
FIG. 19C depicts a cut away side view of the cathode and collector assembly, showing a difference in temperature from the inner current collector end (˜900° C.) and the transition to the outward collector bar end (˜800° C.), adjacent to where the bar exits the cell.
FIG. 20A depicts two bench models of cathode bar materials having an inner void with expandable material. FIG. 20B depicts the expandable bars in an expanded state, with walls expanded in an outward direction.
FIG. 21 depicts an exemplary cutaway side view of a different configuration of an adjustable bar used for the trial depicted in FIG. 22 .
FIG. 22 depicts the trial run of two bench scale adjustable bars, depicting the Pressure (PSIG) as a function of Time (Days).
FIG. 23 depicts a plan side view of an adjustable bar of a second trial run.
FIG. 24 depicts the resulting pressure (PSIG) and Temperature (C) as a function of Time (days).
FIG. 25 depicts the components of Example 5, including the frame, the bench scale adjustable bar and another component prior to assembly into the tested configuration.
FIG. 26 depicts the assembled configuration of Example 5, before testing.
FIG. 27 depicts the assembled configuration for Example 5, after testing.
FIG. 28 is a graphical representation of pressure and temperature vs. time (in days) for Example 5.
Various ones of the inventive aspects noted herein above may be combined to yield electrolysis cells and methods of operating the same to efficiently and effectively produce aluminum while using less electricity, thus lowering operating costs.
These and other aspects, advantages, and novel features of the invention are set forth in part in the description that follows and will become apparent to those skilled in the art upon examination of the following description and figures, or may be learned by practicing the invention.
DETAILED DESCRIPTION
Reference will now be made in detail to the accompanying drawings, which at least assist in illustrating various pertinent embodiments of the instant disclosure.
Referring to FIGS. 1 and 2 , embodiments of an electrolysis cell are generally depicted. During aluminum production, the electrolytic cell 10 produces aluminum (e.g. commercially pure aluminum) at operating conditions. In some embodiments, the electrolysis cell 10 components are housed within a wall 50 (e.g. outer shell), which have refractory blocks (or material) 42 therein to insulate the system and protect the outside environment from leaks of hot electrolytic bath and/or aluminum. In some embodiments, the electrolysis cell 10 includes an anode 12 , a cathode assembly 14 having an adjustable current collector bar 20 , and a liquid medium 40 .
In some embodiments, the cathode assembly 14 refers to the current collector subassembly 20 and the cathode 16 . The current collector subassembly 20 refers to the collector bar 22 , the joint material 50 , and any electrical subassembly for transferring electricity out of the cell (not shown). In some embodiments, the cathode 16 and collector subassembly 20 are in a mated position, where the current collector subassembly 20 is at least partially retained a slot 18 of the cathode 16 . In some embodiments, the ends of the current collector bar(s) 20 extend out from the refractory 42 and wall 50 . As a non-limiting example, the cathode 16 is located at the base of the aluminum electrolysis cell 10 . In some embodiments, the cathode 16 conducts the electrical current and transfers the electrical current (i.e. through its form) to exit the cell 10 via the electrical buswork (not shown). In some embodiments, the current enters the cathode 16 from the liquid medium 40 (e.g. molten electrolyte). In some embodiments, the current enters the cathode 16 from the aluminum metal pad 36 (i.e. which has formed atop the cathode 16 ) during cell operation (aluminum production). During operation, aluminum 36 (i.e. the metal pad) is produced on the surface of the cathode 16 (see, e.g. FIGS. 1 and 2 ).
In some embodiments, the aluminum electrolysis cell 10 has more than one bar, for example, twenty, forty, or eighty. In some embodiments, the anode 12 emits an electrical current into the electrolytic cell 10 and into the liquid medium 40 . As a non-limiting example, the liquid medium 40 includes molten salt electrolyte, and also generally refer to any intermediates, byproducts, or products formed thorough the reaction process of alumina to aluminum. In some embodiments, the electrolyte includes cryolite (Na 3 AlF 6 ) and alumina (Al 2 O 3 ). From the liquid medium 40 , the electrical current acts to produce aluminum 36 within the electrolytic cell 10 . In some embodiments, the electrical current exits the electrolysis cell 10 through the cathode assembly 14 .
In some embodiments, the cathode 16 is constructed of one or more known and accepted materials. In one embodiment, the cathode 16 is carbon (e.g. in block form). In some embodiments, the cathode 16 includes a slot 18 . In some embodiments, the slot 18 is preformed along a lower surface of the cathode 16 . In some embodiments, the slot 18 has a sufficient size dimension so that the current collector subassembly 20 fits at least partially into the slot 18 . In some embodiments, the slot 18 substantially encloses (surrounds) the bar 22 . In some embodiments, the slot 18 surrounds a portion of the bar 22 (some but not all sides) (i.e. bottom exposed). In some embodiments, the adjustable collector bar 22 exerts force (or pressure) onto the adjacent cathode as the inner void of the collector bar are pushed outward (e.g. in a transverse direction). In some embodiments, the collector bar 22 thus expands in a transverse direction to conform to the cathode slot and reduce electrical resistance across the cathode assembly.
Referring to FIG. 1 , in some embodiments, the inner ends of two collector bars are spaced by a spacing material 48 . In one embodiment, the spacing material 48 includes a non-reactive material which is not degraded at operating conditions. As non-limiting examples, the spacing material 48 can include ceramic materials, refractory materials, or the like, and may be in particulate or solid (block) forms between the cathode bar ends.
Referring to FIG. 1 , the current collector subassembly 20 includes the current collector bar 22 and a joint material 52 (e.g. copper insert and/or joint). In some embodiments, the current collector bar 22 extends from one end of the cathode 16 to the other end of the cathode 16 . In some embodiments, the outer end of the bar 22 includes an anchor and/or brace 44 (i.e. to restrict axial movement).
In some embodiments, the current collector bars 22 include anchors 44 which maintain the bars 22 in place (e.g. restrict axial/longitudinal movement). In some embodiments, outward (rigid body) motion of the bars 22 are restrained with anchors 44 which are attached/anchored to the pot lining 42 . In other embodiments, the anchors 44 are attached to the ends or sides of the current collector bars 22 , external to the cell wall 50 .
Referring generally to FIGS. 2-12 , various embodiments of an adjustable current collector bar are depicted, in accordance with the instant disclosure. In some embodiments, the adjustable bar includes a gas 28 and an expandable material 30 . After being heated, the expandable material 30 expands (e.g. via a phase change and/or chemical decomposition) and the gas 28 expands (e.g. via the ideal gas law) increase the inner volume of the inner void 26 and push the walls 24 of the bar outward. In some embodiments, the expandable material 30 completely transforms to gas (e.g. no solid/particulates in the void 26 after heating). In some embodiments, the expandable material 30 degrades or transforms into one or more compositions, where some solid material is left in the void 26 (e.g. after heating).
“Conform”, as used herein, means to adapt the shape and/or size of a first component to that of a second component. For example, a current collector bar 22 conforms to the slot 18 of a cathode 16 due to an increased amount of force applied to the sidewalls 24 by the increased pressure in the inner void 26 of the bar.
In some embodiments, initially, a small amount of the collector bar 22 is in contact with the slot 18 , which leads to poor cell performance. After the conformation, the shape of the collector bar 22 more closely matches the size and/or shape of the slot 18 , leading to an increased amount of direct contact (contact site) between the collector bar 22 and the slot 18 . This increased amount of contact facilitates improved cell 10 performance (e.g. reduced electrical resistance across the cathode to bar joint. The amount of conformation of the current collector subassembly 20 to the slot 18 is measured by a decrease in cathode voltage drop. This indicates a good attachment/connection site and thus, conformation. In some embodiments, cathode voltage drop is typically on the order of about 200 mV to about 500 mV during the operation of the aluminum electrolysis cell 10 . It is believed that at least about up to 100 mV is directly due to poor (loose) electrical contact (between the slot 18 of the cathode 16 and the current collector bar 22 ).
Without being bound to a particular mechanism or theory, by approximating from the ideal gas law, the increase from ambient to operating temperature (from 20° C. to 900° C.) works to increase the pressure of the gas inside the bar. However, there may be reductions in this pressure due to loss of oxygen (e.g. to rust) and subsequent volume increase of the bar (e.g. metal expansion).
In some embodiments, the bar is pressurized (e.g. at room temperature, or at a temperature below cell operating conditions) prior to undergoing an increase in temperature (and increase in pressure). In some embodiments, the bar is pre-pressurized to (i.e. the bar as an initial internal pressure of): at least about 5 psig; at least about 10 psig; at least about 15 psig; at least about 20 psig; at least about 25 psig; at least about 30 psig; at least about 35 psig; at least about 40 psig; at least about 45 psig; at least about 50 psig; at least about 55 psig; at least about 60 psig; at least about 65 psig; or at least about 70 psig. In some embodiments, the bar is pre-pressurized to (i.e. the bar as an initial internal pressure of): not greater than about 5 psig; not greater than about 10 psig; not greater than about 15 psig; not greater than about 20 psig; not greater than about 25 psig; not greater than about 30 psig; not greater than about 35 psig; not greater than about 40 psig; not greater than about 45 psig; not greater than about 50 psig; not greater than about 55 psig; not greater than about 60 psig; not greater than about 65 psig; or not greater than about 70 psig.
In some embodiments, the bar is pressurized to: at least about 5 psig; at least about 10 psig; at least about 15 psig; at least about 20 psig; at least about 25 psig; at least about 30 psig; at least about 60 psig; at least about 80 psig; at least about 100 psig; at least about 120 psig; at least about 140 psig; at least about 160 psig; at least about 180 psig; at least about 200 psig; at least about 220 psig; at least about 240 psig; at least about 260 psig; at least about 280 psig; or at least about 300 psig.
In some embodiments, the bar is pressurized to: not greater than about 5 psig; not greater than about 10 psig; not greater than about 15 psig; not greater than about 20 psig; not greater than about 25 psig; not greater than about 30 psig; not greater than about 60 psig; not greater than about 80 psig; not greater than about 100 psig; not greater than about 120 psig; not greater than about 140 psig; not greater than about 160 psig; not greater than about 180 psig; not greater than about 200 psig; not greater than about 220 psig; not greater than about 240 psig; not greater than about 260 psig; not greater than about 280 psig; or not greater than about 300 psig.
In another embodiment, a small amount of expandable material (e.g. gas 28 , solid expandable material 30 ) is sealed inside the bar, where the material adds to the increase in pressure inside the bar as it heats up (e.g. by a phase change to gas). For example MgCO 3 releases CO 2 gas near 350° C.
In some embodiments, the bar is used with filler material 34 (sometimes called particulate substrates, or inert material) inside bar and/or between the bar ends. Filler material 34 is generally selected from solid materials that maintain stiffness (e.g. rigidity) at elevated temperature and/or materials that do not degrade or decompose at cell operating temperatures. Non-limiting examples of fillers include: tabular alumina, ceramics, copper, and the like. In some embodiments, the bars are welded closed, though other methods of sealing the bars may be employed.
FIG. 13A-13B is a cross sectional side view, of the bar 22 in the slot 18 . FIG. 13A depicts the gap, or low joint surface area/interface ( FIG. 13A , on the left) compared to the high interface/surface area in the joint ( FIG. 13B on the right) once the bar to the slot 18 of the cathode 16 ( FIG. 13B ).
FIG. 14A-14B is a partial cross sectional front view. FIG. 14A depicts the gap, while FIG. 14B depicts in a generally perpendicular direction to the longitudinal axis. In some embodiments, the adjustable current collector bar 22 compresses/conforms itself onto the surface of the cathode slot, via the increase in pressure from the expansion of gas and or material in the inner void. In some embodiments, the bar 22 is sufficiently designed to apply continuous force required to conform the bar to the slot 18 at operation conditions within the aluminum electrolysis cell (e.g. at least about 800° C.).
Referring to FIG. 14B , a detector/sensor 38 is employed in conjunction with an anchor 44 . The detector 38 (e.g. sensor) includes a displacement gauge which detects the amount of compression of the current collector subassembly 20 . In some embodiments, this measurement is completed by measuring the relative length of the current collector bar 52 as it protrudes from the wall of the electrolytic cell 10 . In some embodiments, the amount of expansion/conformation to the cathode by the bar is detected by measuring the force that is imparted by the bar 22 onto the slot 18 . In some embodiments, the induced deformation in the collector bar 22 causes gaps between opposing surfaces in the joint to partially, or fully close. In some embodiments, increasing the amount of area in contact between the cathode 16 subcomponents reduces the electrical contact resistance, to allow electricity to flow from one material to another more easily (i.e. with less resistance).
FIGS. 15A and 15B depict a ‘before’ and ‘after’ view of a large macroscopic gap between the cathode 16 and the current collector bar 22 . In this example, once the bar is pressurized, the gap appears to be completely closed. In another example, when surfaces are non-uniform, as depicted in FIGS. 15C and 15D , the frequency and/or extent of contact between the 16 and the bar 22 is increased between these smaller asperities, but the small gaps from the non-uniform surfaces are not completely eliminated. In some embodiments, the increase in contact area occurs at the interface between: (a) the slot and the joint material; (b) the joint material and the bar (c) the bar and the slot (in the absence of joint material); and (d) combinations thereof.
FIG. 16 depicts an exemplary path of the electrical current from the cathode block 16 as it moves towards the ends of the current collector bars 22 . The electrical current is depicted by arrows. In some embodiments, the current collector bar 22 collects an electrical current from the electrolysis cell 10 (via the cathode 16 ) and transfers the electrical current out of the cell 10 . In some embodiments, the current collector bar 22 is made of various conductive materials. As a non-limiting example, the current collector bar 22 is made of metallic materials (e.g. suitable for conducting electricity). In some embodiments, the current collector bar 22 includes a joint material 52 extending along a portion of the surface of the current collector bar 22 .
The “joint material” 52 refers to a conductive material which promotes better attachment and electrical contact. In some embodiments, the joint material is located between the surface of the current collector bar 22 and the slot 18 of the cathode 16 . Non-limiting examples of joint materials 52 include: metallic sheets, cast iron, copper, and/or adhesives. In some embodiments, the current collector subassembly 20 is partially disposed in the slot 18 to enable removal of electrical current from the electrolysis cell 10 .
In some embodiments, adjustable bar 22 promotes an interface 46 (or a surface) forming a common boundary between two materials. In some embodiments, the interface 46 of the current collector subassembly 20 and the slot 18 of the cathode 16 is improved as the current collector subassembly 20 conforms to the slot 18 , so that electrical current is more effectively transferred from the cathode 16 to the current collector subassembly 20 (i.e. little contribution to cathode voltage drop (CVD)). By “improved”, it refers to the increase in the amount of either macroscopic or microscopic area where the subassembly and the surface of the slot are in direct contact.
EXAMPLES
Creep and Expansion in Cathode Assembly Materials
In order to determine the minimum amount of force necessary to get appropriate creep in the collector bars at operating conditions, experiments were conducted to determine the rate of creep over periods of time for scaled-down samples of collector bar steel at operating conditions with an external force applied.
In some embodiments, at cell operating conditions, too little force may not cause enough deformation to reduce CVD, while too much force may cause the bar to deform to such an extent that the (carbon) cathode block breaks.
FIG. 17 depicts a model results of the voltage loss across different components with joint (contact) resistance adjusted to match average measured CVD values from a number of pot lines in different plants with different pot types.
FIG. 18 depicts how the stress required for creep in the collector bar decreases with increasing temperature, extrapolated to electrolytic cell operating temperatures, plotted as stress versus temperature.
In the system examined, the aluminum electrolysis cell operates at high temperatures and preferably has a low rate of creep. For low creep rates and high temperature, Harper-Dorn dislocation climb is believed to be a good model for secondary creep. The equation for strain rate, {dot over (ε)}, is:
ɛ
.
=
A
HD
G
b
kT
D
0
ⅇ
-
Q
RT
(
σ
G
)
Under the experimental operating conditions, everything in the equation is fairly constant except strain rate {dot over (ε)} and stress (σ), and in the equation these are proportional.
FIG. 19A depicts the different thermal expansion of the cathode block material versus collector subassembly materials (steel and iron) at different temperatures. FIG. 19B depicts an example of the calculated gap (distance, measured in mm) versus temperature (C). FIG. 19C depicts that under operating conditions, the collector bar (of the depicted configuration) exhibits different temperatures along its length (e.g. ˜900° C. towards the inner end, and ˜800° C. towards the outer end (i.e. near where the bar leaves the cathode block, yet still inside the cell wall).
Example 1
Bench Test of Creep in Collector Bar Material
Bench tests were conducted to determine the creep for a certain load/force on the collector bars. In each test, a two inch long, inch diameter rod of 1018 steel was loaded with a 50 pound weight (113 psi). Two tests were conducted, where one sample was held in compression for one week at about 930° C., and the other sample was held at compression for two weeks at about 930° C.
The resulting test specimens became slightly shorter and wider. The first sample gave an axial strain rate of 0.0015%/hr. The second sample gave an axial strain rate of 0.0012%/hr. The widening rate, which is needed to improve the joint, was 0.0019%/hr for the first sample and 0.00074%/hr for the second sample. It should be noted that in the first test the diameters were measured with less precision, which may explain the high value of 0.0019%/hr, as compared to the second sample. These results indicate that with reasonable applied forces onto the current collector bar, widening of the bar into the slot of the cathode block is achievable. It is noted that the tested bars were solid (i.e. did not have inner voids); thus, bars with an inner void are expected to have an increased strain as compared to solid metal bars. Thus, electrical contact is increased, joint resistance is decreased, and CVD is decreased.
Example 2
Bench Test of Adjustable Bar
FIGS. 20A and 20B depict a perspective view of two bench scale bars having inner voids shown side by side. (While these bars are rectangular, other shapes are possible.) FIG. 20A depicts the bars before expansion and FIG. 20B depicts the bars after expansion.
Example 3
Bench Test of Adjustable Bar
Another set of adjustable bars were constructed, both with rounded edges as depicted in the cross-sectional view of FIG. 21 . Both bars had 1 gram of MgCO 3 which released CO 2 resulting in the pressure increase between 350° C. and 450° C. Bar 1 was constructed of ¼″ carbon steel walls, while Bar 2 was constructed of ⅛″ stainless steel walls. For each bar, the walls were sealed with welds. FIG. 22 is a chart that shows the pressure in the two bars over time (delays). While Bar 2 failed (did not retain pressure) due to an inadequate weld, Bar 1 maintained a substantial pressure throughout the trial period.
Example 4
Referring to FIGS. 23 and 24 , another bar was constructed and underwent a 16-day experimental trial. The bar had steel walls that were approximately ⅛ inch thick and the bar was constructed of 304 stainless steel, as depicted in FIG. 23 . The bar faces were made of flat plate, while the rounded sides were cut from half sections of tube. The faces and edges (e.g. rounded edges) were attached by welding. This test bar had nominal external dimensions of 5×3.5×1.25 inches. It contained 1 gram of MgCO 3 , which contributed to the internal pressure by releasing CO 2 gas at the elevated temperature. The test bar was partially constrained during the test, so that the “inflated” thickness of the bar increased only by about ⅜ inch. It should be noted that the pressure tap located near the top of the test bar was only for measuring the internal pressure of the test piece, and did not supply pressure to the test bar.
Throughout the test (over a two-week period), the bar maintained significant pressure at a temperature of approximately 900° C. There were no leaks observed in the bar. It is estimated that this structure, in an electrolysis cell start-up and/or operating conditions, would cause significant (e.g. permanent) deformation of a collector bar in an operating pot, i.e. to prevent, reduce, and/or eliminate a gap between the cathode collector bar(s) at the cathode slot.
Referring to FIG. 24 , the chart plots the internal pressure of the bar and temperature, as a function of time during the test (over an 18 day period). Without being bound to a particular mechanism or theory, the initial increase in pressure to a peak of 91 PSIG was believed to be driven by both the temperature (as per the ideal gas law) and release of CO 2 from the one gram of MgCO 3 powder inside the bar, while the subsequent decrease in pressure was believed to be due to the volume expansion of the test piece, and possibly also due to the absorption of some gas species by the steel (perhaps nitrogen). It was observed that the pressure was extremely steady over the final week of the test (e.g. day 7-˜16) at approximately 46-47 psig (as depicted).
It should be noted that the final drop in pressure (at the end of the test) was due to the drop in temperature (e.g. removal from heat), and not due to a leak. The test piece maintained a reduced positive pressure after the test, (e.g. as would be expected under the ideal gas law.)
Example 5
Bar Deformation of Steel Frame and Block
An experiment was performed to test whether an adjustable bar (e.g. of steel) was capable of enough compression to deform an industrial sized collector bar cross section (e.g. steel, and another steel frame, while maintaining pressure (e.g. not leaking). Referring to FIG. 25 , this bench test used a steel frame (right) to constrain an adjustable bar (left) and a short (4.5″ high) steel bar (middle) with a cross section of (3″×4.5″). The assembled components before the test are depicted in FIG. 26 , while the assembled components after the test are depicted in FIG. 27 .
In order to read the pressure during the experiment, the bar was fitted with a tube leading to a pressure gauge. (In an operating cell, this pressure gauge would be omitted.) The bar contained 4 grams of MgCO 3 , which was believed to decompose and release CO 2 gas (near 350° C.) as the configuration heated up to cell operating temperature of approximately 900° C. The resulting CO 2 which is generated inside the bar in turn pressurized the bar, which, in combination with the elevated temperature conditions, resulting in the bar's walls deforming/bowing outward and imparting pressure (compressing/conforming) the adjacent steel block and frame. FIG. 27 depicts the bar and restraining frame, with the bar and block inserted into the frame. Thermocouples were placed near the inside top and bottom of the frame. Graphite cloth was used between the bar-to frame and block-to-bar contact points to prevent steel pieces from touching and welding together at temperature. The configuration was surrounded by packing coke and an argon purge, to prevent oxidation of the carbon steel frame and steel block bar. The bar was constructed of 304 stainless steel plate and 304L stainless steel tube, both nominally 0.125″ thick. The bar's external dimensions were 4″×5.5″×1.25″.
The steel block was fitted with stainless steel pins for measuring the vertical deformation caused by the adjustable bar. Referring to FIG. 27 , while the vertical compression/conformation of the steel block is not apparent to the naked eye, the bending stresses developed in the restraining frame were high enough to cause visible deformation.
FIG. 28 depicts the average temperature and bar pressure over the course of the test (depicted as a function of time, in days). Referring to FIG. 28 , the temperature was brought up to 600° C. during the first day and then up to 900° C. on the second day, where it stayed for two weeks. Referring to FIG. 28 , the pressure peaked near 250 psig, then decreased rapidly (at first), followed by a more gradual decrease in pressure. By the end of the test, the pressure was at about 30 psig. Without being bound to a particular mechanism or theory, it was believed that some pressure was lost inside of the bar due to surface reactions between the CO 2 generated and the inner steel surface of the bar.
Measurement of the inside and outside pin spacing as well as measurement of the full steel bar height showed a total compressive strain (shortening) of about 0.14% in a longitudinal direction over the course of the test, as depicted in Table 1, below. This would correspond to a fattening across the width (transverse direction) of about 0.07% (which is about half of the strain in the longitudinal direction). Without being bound to a particular mechanism of theory, it is believed that a collector bar is capable of deforming itself to the cathode (e.g. slot) via the increase in pressure in the inner void and by applying that pressure to deform the bar outward, in a transverse direction to conform the bar to the cathode.
TABLE 1
Measurements for total height change and change in average pin position give
total strain during the bench test. Pins were numbered in six vertical pairs.
Full Bar Height at Corners
1-2 Corner
3-4 Corner
4-5 Corner
6-1 Corner
Before
4.634
4.608
4.596
4.623
After
4.6305
4.598
4.586
4.619
Strain
−0.076%
−0.217%
−0.218%
−0.087%
Pins
Pin 1-1
Pin 2-2
Pin 3-3
Pin 4-4
Pin 5-5
Pin 6-6
Outside Before Test
4.0007
3.9998
4.0002
4.0003
3.9996
4.0000
Inside Before Test
3.0030
3.0025
3.0030
3.0040
3.0035
3.0030
Outside After Test
3.9985
3.9985
3.9960
3.9980
3.9920
3.9950
Inside After Test
3.0020
2.9980
2.9970
3.0000
2.9930
2.9960
Strain
−0.046%
−0.083%
−0.146%
−0.090%
−0.258%
−0.171%
Average of all Strains −0.14%
Referring to Table 1, the measurements taken across the width of the block showed fattening (negative strain values refer to a reduction in size in a longitudinal direction, thus an increase in size in a transverse direction).
By extrapolating these results to a larger collector bar (e.g. about 4.25″ wide) in an operating cell (as opposed to a furnace at cell operating temperature), the strain is expected to correspond to a deformation of the block in a transverse direction (bar “fattening”) of roughly 0.003. This was only about half of the expected 0.07%. Without being bound to a particular mechanism or theory, this may be attributed to “end effects” which refers to the changes occurring at one end of the bar and/or the limited number of measurements.
Without being bound to any mechanism or theory, this amount of deformation in the bar is believed to be sufficient to reduce CVD in an operating pot.
Without being bound to any mechanism or theory, this amount of deformation is believed to be approximately one order of magnitude smaller than the air gap which is expected to be formed over a collector bar's surface due to bar bending during rodding (formation of the cathode collector assembly).
Without being bound to any mechanism or theory, this amount of deformation is also believed to be about one half of the interference fit that makes the difference between no contact and perfect electrical contact in a metal to metal contact in other collector bar applications.
Therefore, while more deformation (from pressure being maintained longer) would result in a greater reduction in CVD, the amount of deformation achieved with this configuration is believed to be sufficient to significantly reduce CVD.
Further, without being bound by any mechanism or theory, the Harper-Dorn dislocation climb suggests that creep rate at temperature is proportional to compressive stress. Given the aforementioned, by integrating the pressure history and incorporating the measured creep, it's possible to provide a relationship for the creep rate:
ɛ
.
=
-
1.4
×
10
-
6
p
sig
day
×
σ
While various embodiments of the instant disclosure have been described in detail, it is apparent that modifications and adaptations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and adaptations are within the spirit and scope of the instant disclosure.
REFERENCE NUMERALS
10 cell
12 anode
14 cathode assembly
16 cathode
18 cathode slot
20 current collector subassembly
22 current collector bar
24 sidewall
26 inner void
28 expandable material gas
30 expandable material solid (e.g. phase change)
32 conductive material
34 filler material (non-reactive/non-expansive)
36 metal pad (aluminum metal)
38 compression detector
40 bath
42 lining (refractory lining)
44 anchor/brace
46 interface (e.g. mechanical connection, electrical connection)
48 spacer material (external to bar, e.g. between bars)
50 wall (outer shell)
52 joint material (e.g. between cathode and bar)
54 attached end (e.g. cap on end of collector bar)
56 attachment site (e.g. seal, mechanical connection between portions of the bar) | The instant disclosure provides an electrolysis cell, which includes: an anode; a cathode block; and a current collector bar configured to be at least partially disposed adjacent to and in electrical communication with the cathode block, wherein the bar comprises: at least one sidewall; an inner void enclosed by the sidewall; and an expandable material retained in the inner void via the at least one sidewall, wherein the expandable material is configured to exert pressure on the wall of the inner void while the bar is at operating temperature, such that the bar is conformed to the cathode block. | 89,075 |
BACKGROUND OF THE INVENTION
The present invention relates to a transistor circuit employing insulated gate field effect transistors, and more particularly to a voltage-current converter circuit.
Insulated gate field effect transistors (hereinafter abbreviated as IGFET's) have been widely used. Among their principal application, there exists a current source for supplying or absorbing a predetermined value of current. Such current sources are utilized, for example, as a constant current source for a differential amplifier or a current source for effecting charge or discharge of a time constant circuit. In accordance with improvements in circuit techniques in recent years, a capability of controlling a current value has been desired for a current source. In addition, due to the fact that power supply voltages have become low-voltage, stabilization of an operation at a low voltage and operations over a wide voltage range have been required.
As is well-known, a source-drain current of an IGFET would not vary linearly as a fuction of a gate-source voltage. More particularly, representing a gate-source voltage by V GS , a drain-source current by I DS , a threshold voltage by V T and a current amplification factor by β, when the drain-source voltage V DS fulfils the condition of V DS >V GS -V T , the following relation is established:
I.sub.DS =β(V.sub.GS -V.sub.T).sup.2 ( 1)
and therefore, the drain-source current I DS has a square (the second powered) characteristic with respect to the gate-source voltage V GS . In various applications, this becomes great obstruction in the case where an IGFET is used in a linear circuit for which a linear relation beween a voltage and a current is required.
However, even with IGFET's having such a characteristic, it is possible to contrive to obtain a linear relation between a voltage and a current. Now it is assumed that two IGFET's having respective threshold voltages V T1 and V T2 and an identical current amplification factor β are prepared and a common voltage V GS is applied between their gates and sources. Then, the respective drain-source currents I DS1 and I DS2 are represented by the following equations, similarly to Equation-(1) above:
I.sub.DS1 =β(V.sub.GS =V.sub.T1).sup.2 ( 2)
I.sub.DS2 =β(V.sub.GS -V.sub.T2).sup.2 ( 3)
At this moment, the respective drain-source voltages V DS1 and V DS2 fulfil the relations of V GS1 >V GS -V T1 and V DS2 >V GS -V T2 . Considering now the difference between these currents flowing through the respective IGFET's, from Equations-(2) and -(3) above it can be seen that the following relation is established.
I.sub.DS1 -I.sub.DS2 =2βV.sub.GS (V.sub.T2 -V.sub.T1)+V.sub.T1.sup.2 -V.sub.T2.sup.2 ( 4)
In other words, the difference current between the drain-source currents of the two IGFET's has a linear relationship to the common gate-source voltage V GS . Accordingly, if provision is made such that when the same gate-source voltage is applied to two IGFET's having different threshold voltages and the same current amplification factor, the difference current between the drain-source currents of the respective IGFET's can be detected. Thus, even in a circuit constructed of IGFET's it is possible to realize a linear voltage-current characteristic.
Although a sum of currents flowing through two IGFET's, respectively, can be obtained simply by connecting the IGFET's in parallel, a simple method for obtaining a difference between two currents has not been known.
SUMMARY OF THE INVENTION
It is one object of the present invention to provide a current source circuit which can output a current having a controllable current value.
Another object of the present invention is to provide a linear voltage-current converter circuit.
Still another object of the present invention is to provide a current source circuit having a wide range of operation voltage.
Yet another object of the present invention is to provide a circuit in which a difference current between currents flowing through two IGFET's can be obtained in a relatively simple manner.
According to one feature of the present invention, there is provided a linear voltage-current converter circuit comprising a first load element having one end connected to a first voltage source; a first IGFET having a drain electrode connected to the other end of said first load element, a source electrode connected to a second voltage source and a gate electrode connected to a first input terminal; a second load element having one end connected to said first voltage source; a second IGFET having a drain electrode connected to the other end of said second load element, a source electrode connected to said second voltage source and a gate electrode connected to a second input terminal; a third IGFET having a drain electrode connected to the drain electrode of said second IGFET and a source electrode connected to the source electrode of said second IGFET; a fourth IGFET having a drain electrode connected to an output terminal, a gate electrode connected to the gate electrode of said third IGFET and a source electrode connected to said second voltage source, and a differential amplifier having an inverted input terminal connected to the junction between said first load element and the drain electrode of said first IGFET, an uninverted input terminal connected to the junction between said second load element and the drain electrode of said second IGFET and an output terminal connected to the gate electrode of said third IGFET and the gate electrode of said fourth IGFET; said first and second input terminals being supplied with input voltages such that when said third IGFET is removed, the current flowing through said first load element may become larger than the current flowing through said second load element.
According to another feature of the present invention, there is provided a differential amplifier comprising a first IGFET having a drain electrode connected to a first voltage source, a gate electrode connected to a control terminal and a source electrode connected to a first output terminal; a second IGFET having a drain electrode connected to said first voltage source, a gate electrode connected to said control terminal and a source electrode connected to a second output terminal; a third IGFET having a drain electrode connected to said first output terminal, a gate electrode connected to a first input terminal and a source electrode connected to a second voltage source; a fourth IGFET having a drain connected to said second output terminal, a gate electrode connected to a second input terminal and a source electrode connected to said second voltage source; and means for inversely amplifying a sum of a voltage variation on said first output terminal and a voltage variation on said second output terminal and applying the amplified signal to said control terminal.
In the linear voltage-current converter circuit according to the present invention, a current proportional to an input voltage can be obtained over a wide range of input voltage. By employing such a linear voltage-current converter circuit as a current source for charging or discharging a capacitor in a time constant circuitry of an oscillator, it is possible to realize a variable frequency oscillator.
The linear voltage-current converter circuit according to the present invention can be also utilized effectively in an analog-digital converter for converting an analog input voltage to an analog input current proportional to the input voltage, or on the contrary, in a digital-analog converter for converting an analog output voltage to an analog output current proportional to the output voltage.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned and other features and objects of the present invention will become more apparent with reference to the following description of preferred embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a circuit diagram showing one preferred embodiment of the present invention,
FIG. 2 is a circuit diagram showing another preferred embodiment of the present invention,
FIG. 3 is a diagram showing an input-output characteristic of the preferred embodiment shown in FIG. 2,
FIG. 4 is a circuit diagram showing one example of an amplifier employed in the preferred embodiment illustrated in FIG. 1 or 2.
FIG. 5 is a circuit diagram showing still another preferred embodiment of the present invention,
FIG. 6 is a circuit diagram showing yet another preferred embodiment of the present invention,
FIG. 7 is a circuit diagram illustrating one practical example of the preferred embodiment shown in FIG. 6,
FIG. 8 is a circuit diagram showing a first example of an application of the present invention,
FIG. 9 is a diagram showing an input-output characteristic of a Schmitt trigger circuit in FIG. 8,
FIG. 10 is a circuit diagram showing a second example of application of the present invention,
FIG. 11 is a circuit diagram illustrating one practical example of an oscillator circuit in FIG. 10.
FIG. 12 is a circuit diagram showing a differential amplifier circuit in the prior art,
FIG. 13 is a circuit diagram showing a differential amplifier circuit according to the present invention, and
FIG. 14 is a circuit diagram illustrating one practical example of the differential amplifier circuit in FIG. 13.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now one preferred embodiment of the present invention will be described with reference to FIG. 1. While the description will be made, assuming that the IGFET's used in the preferred embodiment are N-channel type MOSFET's for convenience of explanation, the present invention should not be limited to such type of IGFET's, but the invention could be practiced basically in the same manner even with P-channel type MOSFET's.
In the preferred embodiment shown in FIG. 1, while depletion type MOSFET's Q 5 and Q 6 having their respective gate electrode and source electrode connected together are used as first and second load elements, respectively, the present invention should not be limited to the use of such load elements. The voltage-current characteristics of the first load element Q 5 and the second load element Q 6 are selected to be identical. A first MOSFET Q 1 and a second MOSFET Q 2 have their gate electrodes connected to input terminals 8 and 9, respectively. The characteristics of the first MOSFET Q 1 and the second MOSFET Q 2 are selected such that under the condition where a third MOSFET Q 3 is removed, in the input voltage range for which this circuit must operate, the current flowing from a first voltage source 14 through the MOSFET's Q 5 and Q 1 to ground which forms a second voltage source may become larger than the current flowing from the first voltage source 14 through the MOSFET's Q 6 and Q 2 to ground. This means that under the above-mentioned condition the voltage V 11 at a point 11 is lower than the voltage V 12 at a point 12. A differential amplifier 7 should preferably have a gain of infinity in the ideal case, and it is connected in such polarity that when the voltage V.sub. 11 is lower than the voltage V 12 , the voltage at a point 13 is made more positive. When the voltage V 11 at the point 11 is lower than voltage V 12 at the point 12, the voltage difference is amplified by the differential amplifier 7 to make the voltage at the point 13 more positive, resulting in increase of the drain-source current of the MOSFET Q 3 , and thereby the voltage V 12 is lowered. On the contrary, when the voltage V 11 is higher than the voltage V 12 , the voltage V 13 is lowered, so that the drain-source current of the MOSFET Q 3 decreases, and thereby the voltage V 12 is raised. In this way, the voltages V 11 and V 12 are equalized by negative feedback. Since the current-voltage characteristics of the load elements Q 5 and Q 6 are identical, under the condition where the voltages V 11 and V 12 are equal to each other, the values of the currents flowing through the respective load elements are equal to each other. Accordingly, if the currents flowing through the drain-source paths of the MOSFET's Q 1 , Q 2 and Q 3 are represented by I 1 , I 2 and I 3 , respectively, the relation of:
I.sub.1 =I.sub.2 +I.sub.3
is established, and consequently, the current I 3 becomes equal to the difference between the currents I 1 and I 2 . Since the threshold values of the MOSFET Q 3 and a fourth MOSFET Q 4 are identical, so long as the voltages V 12 , V 13 and V 10 at the points 12, 13 and 10, respectively, fulfil the relations of V 12 >V 13 -V T and V 10 >V 13 -V T , where V T represents the threshold values of the MOSFET Q 3 and MOSFET Q 4 , the current flowing through the drain-source path of the MOSFET Q 3 and the current flowing through the drain-source path of the MOSFET Q 4 are proportional to each other. In other words, in the illustrated circuit, an output current proportional to a difference between the drain-source current of the MOSFET Q 1 and the drain-source current of the MOSFET Q 2 can be derived from the output terminal 10. Furthermore, if the current amplification factors of the MOSFET's Q 3 and Q 4 are adjusted to be equal to each other, then it is also possible to obtain an output current equal to the difference current. Although the ground was used as the second voltage source in the above-described embodiment, the second voltage source should not be limited to such voltage source.
Now another preferred embodiment of the present invention will be described with reference to FIG. 2. In this embodiment, enhancement type MOSFET's Q 5 ' and Q 6 ' having their gates and drains connected in common to a voltage source V DD are used as load elements, and an input voltage V in is applied to input terminals 8 and 9 in common.
In FIG. 2, it is assumed that the voltage of the first voltage source (V DD ) is 10V and the second voltage source is the ground. It is also assumed that all the MOSFET's are of N-channel type, a threshold voltage V T1 of a MOSFET Q 1 is 0.5 V and threshold voltages of MOSFET's Q 2 , Q 3 , Q 4 , Q 5 ' and Q 6 ' are 1.0 V. Current amplification factors β of the MOSFET's Q 1 and Q 2 are selected to be equal to each other. To this end, in the case where mobilities of electrons in the channels of the respective MOSFET's are equal to each other, it is only necessary to select channel width W and channel length L, respectively, to be equal to each other. However, in the case where the threshold voltages V T of the respective MOSFET's are made different by a known technique of ion implantation into the respective channel regions then the electron mobilities are also different between the respective MOSFET's, and hence, their respective W/L ratios are made different by the corresponding amount. The value of the ratio of mobilities is typically 70-100%, and by way of example, assuming that the electron mobility in the MOSFET Q 1 is equal to 90% of the electron mobility in the MOSFET Q 2 , then it is only necessary to select the channel width W of the MOSFET Q 2 to be 0.9 times as small as the channel width W of the MOSFET Q 1 . By way of example, the current amplification factors β of the MOSFET's Q 5 ' and Q 6 ' are selected to be equal to 1/2 of that of the MOSFET Q 2 . To that end, it is only necessary, for example, to design the channel widths W of the MOSFET's Q 5 ' and Q 6 ' to be 0.5 times as small as the channel width W of the MOSFET Q 2 and to design the channel length L of the MOSFET's Q 5 ' and Q 6 ' to that of be equal to that of the MOSFET Q 2 . The current amplification factors β of the MOSFET's Q 3 and Q 4 could be selected arbitrarily, and by way of example, they could be selected to both be equal to the current amplification factor β of the MOSFET Q 2 . To that end, it is only necessary to design the channel widths W and channel lengths L of the MOSFET's Q 3 and Q 4 to be equal to those of the MOSFET Q 2 .
The relation between the input voltage V in and the output current I out in the above-described circuit arrangement is illustrated in FIG. 3. It is to be noted that the output current I out is represented as normalized with respect to the current amplification factor β, of the MOSFET Q 1 . In FIG. 3 is also indicated a current I, flowing through the MOSFET Q 1 . As seen from FIG. 3, while the current I 1 flowing through the MOSFET Q 1 has a large non-linearity, the current I out derived at the output is linear in the input voltage range of 1 V to V 1 , which is equal to about 4 V.
In this circuit arrangement, the lower limit of the input voltage V in is the voltage which makes the MOSFET Q 2 cut off, that is, the threshold voltage V T2 , which is equal to 1.0 V in the assumed case. On the other hand, the upper limit of the input voltage V in is the input voltage V in1 at the moment when the voltage V 11 at the point 11 becomes lower than V in -V T1 and hence the MOSFET Q 1 goes out of the saturated region, and accordingly, the threshold voltage V T (Q.sbsb.5 ' ) must satisfy the relation of V in1 >V T (Q.sbsb.5 ' ). This is always possible by increasing the current amplification factor β of the MOSFET Q 5 ' to a necessary extent. Therefore, under the ideal condition that the MOSFET's Q 1 and Q 2 have perfect square characteristics, the current amplification factors β of the MOSFET's Q 1 and Q 2 are perfectly identical to each other and the gain A of the differential amplifier is infinite, a perfectly linear output current can be obtained with respect to an input voltage V in which falls in the range of V T2 <V in <V in1 . In practice, however, such an ideal condition is impossible to be realized. Hence, a certain deviation from the perfectly linear relationship is necessary.
Among the above-described requirements, it is not so difficult in such an integrated circuit to make the characteristics of the MOSFET's Q 5 ' and Q 6 ' coincide with each other to a practically unobjectionable extent because the configurations of the MOSFET's Q 5 ' and Q 6 ' could be made identical. In addition, with respect to the deviation of the characteristics of the MOSFET's Q 1 and Q 2 from the square characteristics, also their characteristics can be approximated to the square characteristics to a practically unobjectionable extent by elongating the channel lengths to a certain extent. In view of the above-mentioned facts, the remaining two requirements serve as factors of principally limiting the linear characteristics. With regard to the current amplification factors β of the MOSFET's Q 1 and Q 2 , while they can be closely approximated by designing the configurations of the respective MOSFET's to be identical, in the case where more precise coincidence is desired to be realized, it can be realized by preliminarily seeking for a difference in electron mobilities due to a difference in the amount of ion implantation and determining configuration ratios while taking this difference into account. With regard to the requirement for the gain of the differential amplfier, representing the gain of the amplifier by A and the ratios of channel width/channel length of the MOSFET's Q 3 and Q 6 by S 3 and S 6 , respectively, the following equation is fulfilled: ##EQU1## Since the relation of (S 2 /S 6 )>2 is normally satisfied, it can be seen from the equation that a good linearity having a current deviation ratio of 1% is obtained with a gain A of about 50.
A differential amplifier having a gain or a degree of amplification of about 50 can be realized by a simple circuit as illustrated in FIG. 4. In this figure, a gate electrode of a MOSFET Q 11 serves as an uninverted input terminal, while a gate electrode of MOSFET Q 12 serves as an inverted input terminal, and a point 13 serves as an output terminal. Only MOSFET's Q 13 and Q 14 are depletion type MOSFET's, and the other MOSFET's Q 11 , Q 12 , Q 15 , Q 16 and Q 17 are enhancement type MOSFET's. The MOSFET's Q 15 and Q 17 are applied with a bias voltage V 13 at their gates to serve as current sources.
Now additional preferred embodiments of the present invention will be described with reference to FIGS. 5 and 6.
In the preferred embodiment illustrated in FIG. 5, load elements 51 and 52 have constructions similar to the MOSFET's Q 5 and Q 6 in FIG. 1 or similar to the MOSFET's Q 5 ' and Q 6 ' in FIG. 2. MOSFET's Q 51 , Q 52 and Q 53 have the functions equivalent to those of the MOSFET's Q 1 , Q 2 and Q 3 , respectively, in FIG. 1. In this preferred embodiment, there are provided MOSFET's Q 54-1 , Q 54-2 , . . . Q 54-n for deriving a plurality of output currents I out 1, I out 2, . . . I out n. In this instance, it is possible to differently preset the coefficients of variations of the respective output currents I out 1, I out 2, . . . , I out n with respect to the input voltage by varying the ratio of channel width/channel length of the respective MOSFET's Q 54-1 , Q 54-2 , . . . , Q 54-n . The circuit according to this preferred embodiment can be effectively utilized, for example, as a plurality of weighted current sources for feeding a D/A converter or an A/D converter, by respectively weighting the current values of the currents flowing through the MOSFET's Q 54-1 , Q 54-2 , . . . Q 54-n , respectively.
In the preferred embodiment illustrated in FIG. 6, control of gate voltages of enhancement type MOSFET's Q 65 and Q 66 serving as load elements is effected by means of an output of an amplifier 68 which generates an inverted output proportional to a sum of voltages at points 11 and 12. In other words, this preferred embodiment employs active loads as load elements, and in this embodiment a sum of voltages at drain electrodes of input MOSFET's Q 61 and Q 62 is negatively fed back to the gate electrodes of the MOSFET's Q 65 and Q 66 which serve as the active loads. In the embodiment lacking such negative feedback as shown in FIG. 1 or 2, as the input voltage approaches the voltage V DD of the first voltage source, the voltages at the drain electrodes of the input MOSFET's will change in the direction for approaching the voltage V SS of the second voltage source, and eventually the input MOSFET Q 1 goes out of the saturation region, so that it cannot achieve the desired operation. This phenomenon restricts the input voltage range of the circuit shown in FIG. 1 or 2. However, if negative feedback is effected as shown in FIG. 6, the voltage changes at the drain electrodes of the input MOSFET's Q 61 and Q 62 can be suppressed to small changes, and hence the input voltage range can be expanded.
One example of a practical circuit arrangement according to the above-described embodiment is illustrated in FIG. 7. In this circuit arrangement, MOSFET's Q 72 and Q 73 are transistors having the same configuration and the same threshold voltage, and a parallel combined output of these two MOSFET's controls an output of a ratio circuit consisting of a load element 71 and a MOSFET Q 74 .
Now description will be made with regard to examples of application of the circuit according to the present invention. In an oscillator circuit, wherein an oscillation period is determined approximately in proportion to a time required for charging or discharging a capacitor up to a predetermined voltage by means of a current source, by employing the circuit according to the present invention as the current source for charging or discharging the capacitor, one can construct an oscillator circuit in which an oscillation frequency varies in a linear relationship with respect to an input voltage. Such an oscillator circuit is essentially necessary for forming a phase-locked loop (PLL). One example of a circuit arrangement of such an oscillator is illustrated in FIG. 8. In this figure, a MOSFET Q 4 is an output transistor of a circuit 100 according to the present invention, and a MOSFET Q 82 is a transistor having a sufficiently large current amplification factor as compared to that of the MOSFET Q 4 . A Schmitt trigger circuit 14 has an input point 15 and an output point 16. A capacitor 13 has one end connected to the input point 15 and the other end end connected to an arbitrary fixed voltage point. The input-output characteristic of the Schmitt trigger circuit 14 are illustrated in FIG. 9. It is to be noted that in this figure the change of the input voltage V in in the rightward direction along the abscissa and the change of the output voltage V out in the upward direction along the ordinate represent voltage changes in the same direction. Assuming now that the relations of V 2 >V 1 and V 4 >V 3 are satisfied for convenience of explanation, as the input voltage V in is successively increased starting from a voltage lower than the voltage V 1 , at the moment when the input voltage V in has reached the voltage V 2 , the output voltage V out changes from the voltage V 4 to the voltage V 3 , whereas when the input voltage V in is successively decreased starting from a voltage higher than the voltage V 2 , at the moment when it has reached the voltage V 1 , the output voltage V out changes from the voltage V 3 to the voltage V 4 .
In FIG. 8, it is assumed that under the condition where the output voltage V out is equal to V 4 , the MOSFET Q 82 changes the capacitor 13 to bring the input voltage V in up to a fixed voltage V 5 that is higher than V 2 and thereby change the output voltage V out to V 3 , whereas under the condition where the output voltage V out is equal to V 3 , the MOSFET Q 82 is in a cut-off condition, while the MOSFET Q 4 in the circuit 100 of the present invention discharges the capacitor 13, so that the input voltage V in is gradually lowered and eventually it reaches V 1 , when the output voltage V out is again raised to V 4 . If the current amplification factor of the MOSFET Q 82 is so high that the time required for the MOSFET Q 82 to change the capacitor 13 and bring the input voltage V in to V 5 when the output voltage V out is V 4 is sufficiently shorter than the time required for the MOSFET Q 4 to discharge the capacitor 13 and bring the input voltage V in to V 1 when the output voltage V out is V 3 , then the oscillation period of this oscillator circuit is approximately equal to the time required for the current generated at the drain electrode of the MOSFET Q 4 as an output current according to the present invention to discharge the capacitor 13 and change the voltage across the capacitor 13 from V 5 to V 1 .
Another example of similar oscillator circuits is illustrated in FIG. 10. In this figure, MOSFET's Q 22-1 and Q 22-2 are output transistors according to the present invention, and an oscillator circuit 24 is an oscillator circuit whese oscillation period is proportional to the time required for discharging a capacitor 23 by means of an external current source (in this instance, the MOSFET's Q 22-1 and Q 22-2 ). One example of such an oscillator circuit constructed by MOSFET's is illustrated in FIG. 11, in which MOSFET's Q 30 , Q 31 , Q 36 and Q 39 are enhancement type MOSFET's and MOSFET's Q 37 and Q 38 are depletion type MOSFET's.
As described above, according to the present invention a difference between currents flowing through two MOSFET's can be obtained through a relatively simple method, and so, the invention has a great effect in the case where it is desired to derive a difference current as in the case where a linear voltage-current characteristic is desired to realize in a MOSFET circuit.
Now more detailed description will be made on the circuit construction of the active load as used in the preferred embodiment illustrated in FIG. 6.
Heretofore, in a linear integrated circuit employing MOSFET's, a circuit having a common current source similar to that used in an integrated circuit of bipolar transistors has been used as a differential amplifier circuit. One typical example of such a known circuit in the prior art is illustrated in FIG. 12.
In FIG. 12, when voltage variations in the same directions are applied to input terminals 86 and 87, that is, upon applying the so-called in-phase input, a current flowing through a first branch including MOSFET's Q 81 and Q 83 and a current flowing through a second branch including MOSFET's Q 82 and Q 84 are equal to each other. Moreover, the sum of these currents is constant owing to the action of MOSFET Q 85 , so that the currents flowing through the respective branches would not change, and accordingly voltages at output terminals 88 and 89 would not change. Whereas, when voltage variations in the opposite directions are applied to the input terminals 86 and 87, that is, upon applying the so-called differential input, the current flowing through the first branch including the MOSFET's Q 81 and Q 83 and the current flowing through the second branch including the MOSFET's Q 82 and Q 84 are subjected to variations in the opposite directions to each other, so that a difference would be produced between the respective currents, though the sum of the respective currents is held constant owing to the action of the MOSFET Q 85 , and the difference is observed as a voltage difference between output terminals 88 and 89 by the actions of the load elements Q 83 and Q 84 . As described above, the circuit shown in FIG. 12 would not produce any change in the output in response to an in-phase component of the input, but it would amplify only a differential component of the input.
As described above, in order for the heretofore known circuit shown in FIG. 12 to operate as a differential amplifier, it is necessary that a constant current flows through the drain-source path of the MOSFET Q 85 , and in order that the constant current flows independently of the voltage at the junction 93, the MOSFET Q 85 must be held in a saturation region. To that end, representing the threshold voltage of the MOSFET Q 85 by V T85 , the bias voltage applied to the gate electrode of the MOSFET Q 85 by V B and the voltage at the junction 93 by V 93 , it is only ncessary to fulfil the following relation:
V.sub.B -V.sub.T85 <V.sub.93
Accordingly, representing the voltage of the second voltage source by V SS , the voltage V 93 can be lowered to the proximity of the voltage V SS by selecting the bias voltage V B at a value that is only a little larger than V SS +V T85 . However, as the bias voltage V B is lowered for the above-mentioned purpose, the current amplification factor of the MOSFET Q 85 must be increased by the corresponding amount, this means to increase the channel width of the MOSFET Q 85 , and consequently, the geometrical dimensions of the MOSFET Q 85 are increased. Because of this increase of the geometrical dimensions, in practice, the bias voltage V B can be lowered only to the extent of about V SS +2V T85 , and accordingly, the voltage V 92 can be lowered only to the extent of about V SS +V T85 . Since the voltages applied to the input terminals 86 and 87, respectively, must be higher than the voltage V 93 at least by the common threshold voltage V T of the MOSFET's Q 81 and Q 82 , the lower limit of the allowable in-phase input voltages to the differential amplifier circuit shown in FIG. 12 is at most equal to the following value:
V.sub.SS +V.sub.T85 +V.sub.T
Since V T85 is normally equal to the common threshold voltage V T , the in-phase input voltages in this instance cannot be chosen lower than the value that is higher than the voltage V SS of the second voltage source by about twice the threshold voltage V T .
However, recently in a MOSFET integrated circuit the demand for lowering the power supply voltage has been remarkable. Therefore, with the aforementioned fact that in the heretofore known circuit shown in FIG. 12 the lower limit of the in-phase input must take a value that is higher than the second power supply voltage V SS by about twice the threshold voltage of the enhancement type MOSFET, there is a big shortcoming that lowering of the power supply voltage is restricted in view of the necessity of obtaining a sufficiently large in-phase input region.
The concept of the previously discussed active load which has been proposed according to the present invention, can be expanded to a differential amplifier having a novel circuit arrangement which has a broader in-phase input voltage range than the known differential amplifiers in the prior art. One example of improved differential amplifiers according to the present invention will now be described.
In FIG. 13, MOSFET's Q 93 and Q 94 are MOSFET's prepared so as to have manually matched electric characteristics, the source electrode of the MOSFET Q 93 is connected to a first output terminal 88, and the source electrode of the MOSFET Q 94 is connected to a second output terminal 89. The respective drain electrodes are both connected to a first voltage source 80 having a voltage V DD , and the respective gate electrodes are both connected to an output of an amplifier 97. MOSFET's 81 and 82 are also MOSFET's prepared so as to have mutually matched electric characteristics. The drain electrode of the MOSFET Q 81 is connected to the first output terminal 89, its gate electrode is connected to a first input terminal 86 and its source electrode is connected to a second voltage source 91. The drain electrode of the MOSFET Q 82 is connected to the second output terminal 89, its gate electrode is connected to a second input terminal 87 and its source electrode is connected to the second voltage source 91. The amplifier 97 inverts and amplifies the sum of the output voltage at the first output terminal 88 and the output voltage at the second output terminal 89, and applies the amplified voltage to the gates of the MOSFET's Q 93 to Q 94 , respectively.
Now the operation of the preferred embodiment shown in FIG. 13 will be described. The voltage variations in the same direction generated at the output terminals 88 and 89 are inversely amplified by the amplifier 97, and the output of the amplifier 97 is applied to the gates of the MOSFET's Q 93 and Q 94 . The voltage applied to the gate electrodes of the MOSFET's Q 93 and Q 94 in this way acts upon these MOSFET's in the direction for offsetting the voltage variations originally generated at the output terminals 88 and 89. Under the ideal condition that the absolute value of the gain of the amplifier 97 is infinite, the voltage variations in the same direction generated at the output terminals 88 and 89 are perfectly offset, and consequently, no voltage variation occurs at the output terminals 88 and 89. On the other hand, the voltage variations having the same magnitude and opposite directions generated at the output terminals 88 and 89 would not influence the output of the amplifier 97 because the sum of the voltage variations is zero, and hence the voltage variations would not be offset. Voltage variations in the same direction applied to the input terminals 86 and 87, that is, the so-called in-phase input voltages art to generate voltage variations in the same direction at the output terminals 88 and 89, and therefore, in this case the voltages at the output terminals 88 and 89 would not be altered by the action of the amplifier 97, as described above. On the other hand, voltage variations in the opposite directions applied to the input terminals 86 and 87, that is, the so-called differential input voltages act to generate voltage variations in the opposite directions at the output terminals 88 and 89, and hence these voltage variations would not be offset as described above. As discussed above, the illustrated circuit is provided with desired characteristics as a differential amplifier circuit which amplifies only a differential input without generating any variation at the outputs in response to an in-phase input.
Considering now the limit of the in-phase input voltages for sustaining the operation of the illustrated differential amplifier when the in-phase input voltages are made to approach the voltage of the second voltage source 91 in the preferred embodiment shown in FIG. 13, the differential amplifier is operable until the MOSFET Q 81 or Q 82 becomes cut off, and accordingly, the differential amplifier can operate until the in-phase input voltages reach the voltage that is higher in N-channel elements or lower in P-channel elements than the voltage of the second voltage source 91 by the threshold voltage of the MOSFET's Q 81 and Q 82 . Recalling now the fact that in the heretofore known differential amplifier illustrated in FIG. 12 the in-phase input voltages were allowed to approach the voltage of the second voltage source 91 only as close as about twice the threshold voltage of the MOSFET's, the advantage obtained by the preferred embodiment of the present invention illustrated in FIG. 13 will be quite obvious.
In the circuit shown in FIG. 13, even if MOSFET's, resistor elements or other elements for adjusting a frequency response are disposed between the drain electrode of the MOSFET Q 93 and the first voltage source 80 and between the drain electrode of the MOSFET Q 94 and the first voltage source 80, or between the drain electrode of the MOSFET Q 81 and the output terminal 88 and between the drain electrode of the MOSFET Q 82 and the output terminal 89, and the respective locations are connected via these elements, so long as they are conductively communicated with respect to D.C. currents, these connections would not interfere with the effect of the present invention. However, it is not favorable to connect resistor elements or other elements between the source electrodes of the MOSFET's Q 81 and Q 82 , respectively, and the second voltage source 91, because the allowable range of the in-phase input is narrowed by the amount equal to the voltages appearing across these connected elements. In addition, it must be carefully done to connect other elements between the source electrode of the MOSFET Q 93 and the output terminal 88 and between the source electrode of the MOSFET Q 94 and the output terminal 89, because sometimes the variations at the output of the amplifier 97 would be hardly reflected to the voltage variations at the output terminals, and in the case where the gain of the amplifier 97 is finite, the variations of the outputs in response to an in-phase input could not be sufficiently suppressed.
FIG. 14 shows a more detailed circut arrangement of the embodiment illustrated in FIG. 13. The circuitry consisting of MOSFET's Q 101 , Q 102 , Q 103 , Q 104 and Q 105 in FIG. 14 is one example of a practical circuit arrangement of the amplifier 97 in FIG. 13. The MOSFET's Q 101 and Q 102 are MOSFET's prepared so as to have mutually matched electric characteristics, their respective drain electrodes are both connected to the first voltage source 80, their respective source electrodes are both connected to a junction 46, and their gate electrodes are respectively connected to a first output terminal 88 and a second output terminal 89. The drain electrode of the MOSFET Q 103 is connected to the junction 46, its source electrode is connected to the second voltage source 91, and its gate electrode 47 is applied with a bias voltage. The gate electrode of the MOSFET Q 104 is connected to the junction 46, and the source electrode thereof is connected to the second voltage source 91. The MOSFET Q 105 is a load element, its drain electrode is connected to the first voltage source 80, and its source electrode and gate electrode are connected to the drain electrode of the MOSFET Q 104 and also connected to the gate electrodes of the MOSFET's Q 93 and Q 94 . The circuitry consisting of the MOSFET's Q 101 , Q 102 and Q 103 form a source-follower circuit which responds the sum of the voltage variations applied to the gate electrodes of the MOSFET's Q 101 and Q 102 , respectively, to derive an output at the junction 46, and the above-referred sum of the voltage variations is transmitted to the subsequent stage as a voltage variation at the junction 46. The MOSFET's Q 104 and Q 105 form a so-called inverter, which inverts and amplifies the voltage variation at the junction 46 and applies the invertedly voltage change to the gate electrodes of the MOSFET's Q 93 and Q 94 . Accordingly, the circuitry consisting of the MOSFET's Q 101 , Q 102 , Q 103 , Q 104 and Q 105 can achieve the desired amplifier operation.
As described in detail above, according to the present invention there is provided a differential amplifier circuit which has a broader in-phase input voltage range that the differential amplifiers in the prior art, and especially, the present invention can provide a great advantage upon lowering the power supply voltage. | A linear voltage-current converter circuit having a simplified circuit structure and operable over a wide voltage range is disclosed. The circuit comprises a first transistor having a drain connected to a power voltage through a first load element, a second and a third transistor having drains connected to the power voltage through a second load element, means for supplying gates of the first and second transistor with voltage signal, means responsive to a voltage difference at drains of the first and second transistors for controlling a gate voltage of the third transistor so as to reduce the voltage difference to zero, an output transistor, and means for supplying a gate of the output transistor with the same voltage as the gate voltage of the third transistor. | 42,151 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent application Ser. No. 61/706,302 entitled “Bowel Cleansing Preparations,” which was filed Sep. 27, 2012. The entirety of the aforementioned application is herein incorporated by reference.
FIELD OF THE INVENTION
[0002] This disclosure pertains to internal medicine, gastroenterology, and more specifically, to bowel cleansing.
BACKGROUND
[0003] Colorectal cancer (CRC) is a leading cause of cancer death. The lifetime risk of developing CRC in the US approaches 6%, and almost half of those affected will die of the disease. Despite the usefulness of screening procedures for its detection, CRC is a major cause of morbidity and mortality. In screening procedures for CRC such as sigmoidoscopy, colonoscopy and radiography, it is important that the colon be thoroughly purged and cleansed. In particular, it is essential that as much fecal matter and fluids as possible be removed from the colon to permit adequate visualization of the intestinal mucosa.
[0004] Large volume (4 L) orally administered compositions (e.g., NuLYTELY®, TriLyte® containing polyethylene glycol (PEG) in solution) have been developed for use as gastrointestinal washes for diagnostic purposes or for use as cathartic laxatives. Because the solutions are isotonic, patients are required to ingest a significant volume of these solutions, up to one eight ounce glass every ten minutes for a total of one gallon of fluid, to achieve effective purging. However, the large volume required for effective use of this type of lavage formulation is frequently associated with distention, nausea, cramping, vomiting, and significant patient discomfort. Thus, while these formulations are generally effective, they are not well tolerated. Without close supervision, many patients do not take the complete course of preparation.
[0005] Small volume (about 300 ml) solutions containing concentrated sodium sulfate and phosphate salts taken in tablespoon size (15 ml) daily amounts have been used as laxatives. An example of this use is (containing sodium sulfate). However, because of their small volumes, when used in this fashion they do not sufficiently clean the colon for diagnostic or surgical procedures.
[0006] In an attempt to avoid the problems associated with the high volume types of preparations, ingestible preparations that consist of aqueous solutions of concentrated phosphate salts have been utilized. The aqueous phosphate salt concentrate produces a tremendous osmotic effect on the intra-luminal contents of the bowel, and therefore, evacuation of the bowel occurs with a large influx of water and electrolytes into the colon from the body. These phosphate salt preparations have been developed for the purpose of decreasing the volume required in colonic purgations. One such preparation comprises 480 g per liter monobasic sodium phosphate and 180 g per liter dibasic sodium phosphate in stabilized buffered aqueous solution, and is sold under the brand name Fleet's Phospho-Soda®.
[0007] Additionally, non-aqueous tablet or capsule formulations of sodium phosphates and sulfates have been used (U.S. Pat. Nos. 5,997,906, 6,162,464, and 5,616,346). These small volume sulfate/phosphate solutions and non-aqueous formulations have been shown to cause massive electrolyte and fluid shifts that are clinically significant to the patient ( US Food and Drug Administration, Center for Drug Evaluation and Research , Sep. 17, 2001; 2002 Physician's Desk Reference , prescribing information for Fleet's Phospho-Soda® and InKine Pharmaceutical's Visicol®).
[0008] HalfLytely® and Bisacodyl Tablets Bowel Prep Kit (HalfLytely®) was developed with the goal of reducing the volume of isotonic solution and thereby improving patient compliance. This successful method uses a laxative amount of bisacodyl, which stimulated initial debulking of the colon, prior to the ingestion of 2 L of polyethylene glycol and isotonic electrolyte solution (PEG-ELS). Although volume-related preparation symptoms were greatly reduced with the use of the lower volume HalfLytely® compared to the use of 4 L NuLYTELY®, the bisacodyl component of the preparation has been associated with patient complaints of abdominal cramping, a known adverse event of bisacodyl, as well as rare reports of ischemic colitis.
[0009] Thus, what is needed is a reduced-volume preparation designed to be completed over a short duration, while not stimulating abdominal cramping or producing the dangerous adverse side effects associated with sodium phosphate based bowel preparations, and which effectively cleanses the colon.
SUMMARY
[0010] It has been discovered that hypertonic aqueous solutions of sulfates, in combination with isotonic solutions of an osmotic laxative, such as polyethylene glycol (PEG) or PEG, and electrolytes, can effectively cleanse the gastrointestinal tract of a patient in a short period of time (relative to bisacodyl/PEG-based preparations), while not stimulating abdominal cramping or producing the renal injury or clinically significant electrolyte shifts associated with phosphate-based bowel preparation. This discovery has been exploited to produce the methods of the present disclosure
[0011] In one aspect, the disclosure provides a method for rapidly cleansing the small and large intestines and colon of a patient. The method comprises; orally administering an effective amount of an aqueous hypertonic sulfate solution to the patient to induce purgation, the solution not producing clinically significant electrolyte shifts, and not containing phosphates; and orally administering an effective amount of an aqueous isotonic solution containing an osmotic laxative to induce purgation. The purgations induced by the solutions administered results in intestinal and colonic cleansing in less than about four hours from the administration of the sulfate solution.
[0012] In some embodiments, the aqueous, hypertonic solution comprises Na 2 SO 4 , K 2 SO 4 , and MgSO 4 . In certain embodiments, the aqueous, hypertonic solution consists essentially of Na 2 SO 4 , K 2 SO 4 , and MgSO 4 . In some embodiments, the aqueous, hypertonic solution comprises about 8 g to about 26.5 g of Na 2 SO 4 , about 1.5 g to about 4.7 g of K 2 SO 4 , and about 1 g to about 2.4 g of MgSO 4 . In certain embodiments, the aqueous, hypertonic solution consists essentially of about 8 g to about 26.5 g of Na 2 SO 4 , about 1.5 g to about 4.7 g of K 2 SO 4 , and about 1 g to about 2.4 g of MgSO 4 . In particular embodiments, the aqueous, hypertonic solution contains about 72.9 mM to about 233 mM sulfate ion. In one embodiment, the aqueous, hypertonic solution comprises about 155 mM sulfate ion.
[0013] In some embodiments, the aqueous isotonic solution comprises PEG, and in certain embodiments, the PEG is PEG 3350. In some embodiments, the aqueous, isotonic solution comprises from about 105 g to about 315 g PEG. In one embodiment, the aqueous, isotonic solution comprises about 118 g PEG, and in another, the aqueous isotonic solution comprises about 210 g PEG.
[0014] In certain embodiments, the aqueous, isotonic solution further comprises Na 2 SO 4 , Na 2 CO 3 , NaCl, and KCl. In some embodiments, the aqueous, isotonic solution further comprises about 5.0 g to about 18.0 g Na 2 SO 4 , about 1.7 g to about 5.5 g Na 2 CO 3 , about 1.5 g to about 4.4 g NaCl, and about 0.75 g to about 2.3 g KCl. In a particular embodiment, the aqueous, isotonic solution further comprises about 11.37 g Na 2 SO 4 , about 3.37 g Na 2 CO 3 , about 2.93 g NaCl, and about 1.5 g KCl.
[0015] In other embodiments, the aqueous, isotonic solution further comprises Na 2 CO 3 , NaCl, and KCl. In some embodiments, the aqueous, isotonic solution further comprises about 1.4 g to about 4.3 g Na 2 CO 3 , about 2.8 g to about 8.4 g NaCl, and about 0.4 g to about 1.1 g KCl. In a particular embodiment, the aqueous, isotonic solution further comprises about 2.8 g Na 2 CO 3 , about 5.6 g NaCl, and about 0.74 g KCl.
[0016] In yet other embodiments the aqueous, isotonic solution further comprises ascorbic acid, sodium ascorbate, Na 2 SO 4 , NaCl, and KCl. In certain embodiments, the osmotic laxative comprises about 2.0 g to about 5.0 g ascorbic acid, about 2.0 g to about 7.0 g sodium ascorbate, about 3.5 g to about 8.0 g Na 2 SO 4 , about 1.2 g to about 3.0 g NaCl, and about 0.25 g to about 1.5 g KCl. In some embodiments, the isotonic solution comprises about 2.35 g to about 4.7 g ascorbic acid, and about 2.95 g to about 5.9 g sodium ascorbate, about 3.75 g to about 7.5 g Na 2 SO 4 , about 1.345 g to about 2.691 g NaCl, and about 0.507 g to about 1.015 g KCl.
[0017] In some embodiments, about 100 ml to about 900 ml of the aqueous, hypertonic sulfate solution is administered, and in other embodiments, about 100 ml to about 500 ml of the aqueous, hypertonic sulfate solution is administered. In a particular embodiment, about 330 ml or about 480 ml of the aqueous, hypertonic sulfate solution is administered.
[0018] In some embodiments about 1 L to about 3 L of the aqueous isotonic solution is administered. In particular embodiments, about 2 L of the aqueous isotonic solution is administered.
[0019] In certain embodiments the aqueous, isotonic solution is administered immediately after ingestion of the aqueous, hypertonic sulfate solution. In other embodiments, the aqueous, isotonic solution is administered about 0.5 hour to about 2 hours after ingestion of the aqueous, hypertonic sulfate solution. In some embodiments, the aqueous, isotonic solution is administered about 1 hour to about 2 hours after ingestion of the aqueous, hypertonic sulfate solution.
[0020] In other embodiments, water is orally administered immediately after or within 2 hours after the step of orally administering the aqueous, hypertonic sulfate solution. In other embodiments, the water is administered after the isotonic solution is administered.
[0021] In another aspect, the disclosure provides a method for rapidly cleansing the small and large intestines and colon of a patient. The method comprises: orally administering about 100 ml to about 900 ml of an aqueous hypertonic solution consisting essentially of about 17.5 g Na 2 SO 4 , about 1.6 g MgSO 4 , and about 3.1 g K 2 SO 4 to induce purgation, the solution not producing any clinically significant electrolyte shifts, and not containing phosphates; orally administering water; and then orally administering from about 1 L to about 3 L of an aqueous, isotonic solution comprising about 168 g PEG, about 11.37 g Na 2 SO 4 , about 3.37 g Na 2 CO 3 , about 2.93 g NaCl, and about 1.985 g KCl to induce purgation. The purgations induced by the solutions administered result in intestinal and colonic cleansing in less than about four hours from the administration of the sulfate solution.
[0022] In another aspect, the disclosure provides a method for rapidly cleansing the small and large intestines and colon of a patient. The method comprises: orally administering about 100 ml to about 900 ml of an aqueous hypertonic solution consisting essentially of about 17.5 g Na 2 SO 4 , about 1.6 g MgSO 4 , and about 3.1 g K 2 SO 4 to induce purgation, the solution not producing any clinically significant electrolyte shifts, and not containing phosphates; orally administering water; and then orally administering from about 1 L to about 3 L of an aqueous, isotonic solution comprising about 210 g PEG, about 2.86 g Na 2 CO 3 , about 5.6 g NaCl, and about 0.74 g KCl to induce purgation. The purgations induced by the solutions administered result in intestinal and colonic cleansing in less than about four hours from administration of the sulfate solution.
DESCRIPTION
[0023] The issued U.S. patents, allowed applications, published foreign applications, and references that are cited herein are hereby incorporated by reference in their entirety to the same extent as if each was specifically and individually indicated to be incorporated by reference. Patent and scientific literature referred to herein establishes knowledge that is available to those of skill in the art.
DEFINITIONS
[0024] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.
[0025] For convenience, certain terms employed in the specification, examples, and appended claims are collected here. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. The initial definition provided for a group or term herein applies to that group or term throughout the present specification individually or as part of another group, unless otherwise indicated.
[0026] The articles “a” and “an” are used herein to refer to one or to more than one (i.e., to at least one) of the grammatical object of the article. By way of example, “an element” means one element or more than one element.
[0027] The term “or” is used herein to mean, and is used interchangeably with, the term “and/or,” unless context clearly indicates otherwise.
[0028] The term “about” is used herein to mean a value − or +20% of a given numerical value. Thus, about 60% means a value of between 60%−20% of 60 and 60%+20% of 60 (i.e., between 48% and 72%).
[0029] The term “composition” refers to a sulfate-containing pharmaceutical material or product which can be in the form of a solution, suspension, tablet, capsule, or powder.
[0030] The term “aqueous hypertonic solution” is used herein to refer to a water-based mixture of poorly absorbable sulfate salts that creates an osmotic pressure gradient between the bowel and bodily fluids large enough to induce the movement of water from the body into the bowel, thereby producing a purgation.
[0031] The term “isotonic solution” is used herein to refer to a solution that has the same salt concentration or the same effective osmotic concentration as found in cells in the body.
[0032] The terms “cleansing” and “colonic cleansing” are used herein to refer to removal of stool material from the bowel such that the bowel can be effectively examined, e.g., by colonoscopy or sigmoidoscopy. One nonlimiting step performed to achieve at least partial cleansing is colonic purgation, and more than one colonic purgation resulting in colonic cleansing.
[0033] The term “purgation” is used herein to refer to an evacuation of a copious amount of stool from the bowels after administration of a laxative.
[0034] The term “clinically-significant” is used herein to refer to electrolyte and fluid shifts which are massive movements of electrolytes and fluids causing alterations in blood chemistry that are outside the normal upper or lower limits of their normal range, and which cause adverse clinical effects (such as renal and/or cardiac disturbances and disturbances caused by sodium phosphate) as determined by a medical professional.
[0035] The term “abnormal values” is used herein as values that are outside the upper or lower limits of a determined normal range.
[0036] The phrase “effective amount” as used herein means that amount of one or more agent, material, or composition comprising one or more agents according to the present disclosure that is effective for producing some desired effect in an animal. More particularly, in the present disclosure, an “effective amount” is that amount and combination of salts necessary to produce a colonic purgation while not producing clinically significant electrolyte shifts. In general, it is recognized that when an agent is being used to achieve a therapeutic effect, the actual amount which comprises the “effective amount” will vary depending on a number of conditions including, but not limited to, the physical form of the composition being administered (such as a solution or tablet), the particular condition being treated, the severity of the disease, the size and health of the patient, and the route of administration. A skilled medical practitioner can readily determine the appropriate amount using methods well known in the medical arts (e.g., see, e.g., Remington: The Science and Practice of Pharmacy (20 th ed) Limmer, Editor, Lipincott, Williams, & Wilkins (2000)).
[0037] In one nonlimiting example, an “effective amount” pertains to an amount of a sulfate solution which, after administration or ingestion, at least induces purgation of the GI tract of its contents. In another nonlimiting example, an “effective amount” pertains to an amount of an aqueous isotonic solution which, after administration to a patient, induces purgation, and which, along with the sulfate solution, can ultimately result in cleansing the GI tract. The “effective amount” may be administered at one time or at multiple times.
[0038] The phrase “pharmaceutically acceptable” is employed herein to refer to those compounds, materials, compositions, and/or dosage forms which are, within the scope of sound medical judgment, suitable for use in contact with the tissues of human beings, animals and plants without excessive toxicity, irritation, allergic response, or other problem or complication, commensurate with a reasonable benefit/risk ratio.
[0039] A “patient” is a mammal, such as a human, cow, dog, cat, horse, rat, rabbit, etc.
[0040] The terms “administrating” and “ingesting” are used interchangeably to refer to the oral provision of something to the gastrointestinal tract of a patient.
[0041] It has been discovered that hypertonic aqueous solutions of sulfates, in combination with an isotonic solution of an osmotic laxative, such as polyethylene glycol (PEG) or PEG and electrolytes, can effectively cleanse the colon in a short period of time (relative to bisacodyl/PEG-based preparations), while not stimulating abdominal cramping or producing the renal injury or clinically significant electrolyte shifts associated with phosphate-based bowel preparation.
[0042] The aqueous, hypertonic sulfate solution does not contain phosphates but contains inorganic sulfate in total amounts ranging from 125 mM to 250 mM, such as about 154 mM. The sulfate can be in the form of various sulfate salts, which, when in solution and in combination, are in ionic form and are effective to produce colonic purgation while maintaining an electrolyte balance. For example, useful sulfate salts include Na 2 SO 4 , MgSO 4 , and K 2 SO 4 . The amounts of the sulfate salts may differ in order to provide electrolyte balance within the body. For example, Na 2 SO 4 may be present from about 0.01 g to about 40.0 g, from about 0.1 g to about 20.0 g, from about 1.0 g to 10.0 g, or from about 8 g to about 26.5 g. Administered amounts of MgSO 4 may be from about 0.01 g to about 40.0 g, from about 0.1 g to about 20.0 g, from about 1.0 g to about 10.0 g, or from about 1.5 g to about 4.7 g. Administered amounts of K 2 SO 4 may be from about 0.01 g to about 20.0 g, from about 0.1 g to about 10.0 g, from about 0.5 g to about 5.0 g, or from about 1.0 g to about 2.4 g.
[0043] For administration, the sulfate salts are dissolved in a volume of water to produce a hypertonic aqueous solution. A volume of less than 1 L of water is well tolerated by most patients, and volumes of less than 500 ml, such as about 100 ml and about 500 ml, about 200 ml to about 450 ml, and from about 300 ml to about 400 ml are useful. For example, a volume of 330 ml is useful as an oral form.
[0044] Following ingestion of the aqueous, hypertonic sulfate solution, an aqueous isotonic, electrolyte-balanced aqueous solution of an osmotic laxative agent is administered and orally ingested. This isotonic solution is administered immediately, up to about 10 minutes, up to about 20 minutes, up to about 30 minutes, up to about 40 minutes, up to about 50 minutes, up to about 60 minutes, up to about 70 minutes, up to about 80 minutes, up to about 90 minutes, up to about 100 minutes, up to about 110 minutes, or up to about two hours after the hypertonic sulfate solution is administered.
[0045] One useful osmotic laxative is PEG, which ranges in molecular weight from about 3000 D to about 8000 D. For example, PEG 3350 is a useful osmotic laxative. In some embodiments, from about 100 g to about 300 g, from about 105 g to about 315 g, from about 150 g to about 300 g, from about 200 g to about 350 g, or from about 105 g to about 315 g of PEG are administered in an aqueous, isotonic solution. In some nonlimiting examples, about 118 g of PEG 3350 are used, and in others, about 210 g of PEG are used.
[0046] The PEG is dissolved in an aqueous solution having a volume of from 0.5 L to about 3 L. In some examples, the PEG administered is in a volume of from about 1 L to about 3 L, from about 1.2 L to about 2.9 L, from about 1.3 L to about 2.8 L, from about 1.4 L to about 2.7 L, from about 1.5 L to about 2.6 L, from about 1.5 L to about 3 L, or from about 1.5 L to about 2.5 L. In one example, the PEG is dissolved in 2 L of an aqueous solution.
[0047] The PEG solution may contain electrolytes to maintain electrolyte balance within the body. Electrolytes, such as NaCl, KCl, Na 2 CO 3 , and/or Na 2 SO 4 in such concentrations that are found within normal cells in the body, are used. In one non-limiting example, 2.86 g Na 2 CO 3 , about 5.6 g NaCl, and about 0.74 g KCl are used. Sodium sulfate, sodium ascorbate, and/or ascorbate acid are also useful in combination with at least some of these salts.
[0048] Useful amounts of electrolyte salts include from 1.5 g to 4.4 g NaCl, from 0.75 g to 2.3 g KCl, from 1.7 g to 5.5 g Na 2 CO 3 , from 5.0 g to 18.0 g Na 2 SO 4 , from 2.3 g to 4.7 g ascorbic acid, and/or from 2.7 g to 6.0 g sodium ascorbate.
[0049] For example, electrolyte-containing osmotic PEG solutions such as NuLYTELY® (PEG, NaCl, KCl, Na 2 CO 3 , Na 2 SO 4 ) (Braintree Laboratories, Inc., Braintree, Mass.) or GoLYTELY® (PEG, NaCl, KCl, Na 2 CO 3 ) (Braintree Laboratories, Inc., Braintree, Mass.) and MoviPrep® (PEG, Na 2 SO 4 , NaCl, KCl, ascorbic acid, sodium ascorbate) (Salix Pharmaceuticals, Inc., Raleigh, N.C.) are useful. To maintain electrolyte balance, changes in the salt concentrations may accompany changes in the PEG concentration.
[0050] Water may be orally administered in some cases directly or from 0-2 hours after administration of the sulfate solution. In addition or alternatively, water may be orally administered after the isotonic solution.
[0051] The sulfate salt solutions such as those described herein were investigated for their efficacy as colon debulking agents because bisacodyl has been associated with reports of abdominal cramping. Four different solutions were prepared with varying amounts of sodium, magnesium, and potassium sulfate salts and each containing a total sulfate amount of 125 mM. The sulfate salt composition of each solution is shown in Table 1.
[0000]
TABLE 1
Composition of Sulfate Formulations
mMole
Soln 1
Soln 2
Soln 3
Soln 4
Na 2 SO 4
142.5
114
128
128
MgSO 4
0
0
0
8.3
K 2 SO 4
20
16
18
18
Volume (ml)
165
165
165
100
[0052] To demonstrate that these sulfate solutions are effective for colonic purgation without producing clinically significant electrolyte and fluid shifts, 27 normal volunteers were given one amount of a laxative which was either one of four different experimental sulfate solutions or another known laxative, or bowel cleansers. These included bisacodyl (20 mg), a PEG and balanced electrolyte isotonic preparation (NuLYTELY®, (2 L or 4 L) or HalfLytely®+Bisacodyl Bowel Prep Kit, (2 L PEG and electrolytes and 10 mg bisacodyl). Bowel movements and urine were collected for 24 hours. The stool output of the subjects were compared and evaluated for movement of electrolytes between the solution and the subject.
[0053] The results measured were mean stool volume output and are shown below in Table 2 using non-sulfate laxatives and in Table 3 using sulfate laxatives.
[0000]
TABLE 2
Mean Stool Volume Output Using Non-Sulfate Laxatives
Bisacodyl
2 L
4 L
20 mg
NuLYTELY ®
NuLYTELY ®
HalfLytely ®
N
11
6
4
7 1
Output
757
1659
3861
2403
(g)
(SD)
(260)
(231)
(168)
(577)
% Solids
50.4
15.0
4.8
2.6
(SD)
(18.7)
(11.2)
(4.5)
(2.2)
1 One patient in the HalfLytely ® group did not have their percent solids measured so sample size was 6.
[0000]
TABLE 3
Mean Stool Volume Output Using Sulfate Formulations
Soln. 4 +
Soln. 1
Soln. 2
Soln. 3
Soln. 4
PEG
n
1
1
3
5
1
Output (g)
1536
1080
1082
1308
2298
(SD)
(215)
(281)
% Solids
3.6
10.7
14.1
12.0
1.4
(SD)
(4.0)
(2.1)
[0054] As shown in Tables 2 and 3, the sulfate formulations produced greater stool output and lower percent stools solids than 20 mg of bisacodyl, indicating that sulfate is an effective debulking agent if ingested prior to the administration of an isotonic solution of PEG. In addition, combining sulfate Soln. 4 with 2 L NuLYTELY® yields results equivalent to the approved bowel preparation, HalfLytely®. This was confirmed by the results obtained when Soln. 4 was administered followed by 2 L of another PEG and electrolyte solution (NuLYTELY®).
[0055] To determine if the present method caused significant electrolyte changes, blood samples were taken from participants about 2 hours prior to ingestion of the laxative and then 2 hours after ingestion. Various analytes in serum were measured and were in the normal range. The sulfate formulation had little or no effect on any of the analytes measured, including serum osmolality and serum electrolytes.
[0056] The sulfate formulation was further refined in another study (Patel, et al. (2009) Am. J. Gastroenterol. 104(4):953-65) which showed that the sulfate formulation is equivalent to the marketed bowel preparations NuLYTELY® and EZPrep®.
[0057] The safety and efficacy of the sulfate/PEG method was then further compared to the FDA-approved Bisacodyl/PEG (HalfLytely®) method in a clinical study, as described in the examples below. The use of the present sulfate/PEG method resulted in a significantly shorter preparation time than use of the Bisacodyl/PEG method (averaging 3.7 hours compared to 5.5 hours) with no statistically significant differences between the methods with respect to treatment-emergent adverse effects. Finally, the present sulfate/PEG method achieved significantly greater “Excellent” preps and a better average cleansing than the Bisacodyl/PEG method. Accordingly, the present method is a highly improved alternative to existing bowel cleansing methods.
[0058] Reference will now be made to specific examples illustrating the disclosure. It is to be understood that the examples are provided to illustrate exemplary embodiments and that no limitation to the scope of the disclosure is intended thereby.
EXAMPLES
Example 1
Sulfate/PEG vs. Bisacodyl/PEG Treatment
A. Formulations Tested
[0059] The “sulfate salt/PEG” preparation included a 16 ounce (330 ml) aqueous, hypertonic sulfate solution containing 125 mM sulfate, total (17.510 g Na 2 SO 4 , 1.6 g MgSO 4 (anhydrous), and 3.13 g K 2 SO 4 ) diluted up to 16 ounces (170.41 g) of purified water. Flavoring and preservatives known in the art can optionally be added as well. This solution can be made from a concentrated 6 ounce solution, and diluted up to 16 ounces with purified water.
[0060] The 2 L aqueous, isotonic PEG solution contains 210 g PEG 3350, 5.6 g NaCl, 2.86 g NaCo3, and 0.74 g.
[0061] The “bisacodyl/PEG” preparation (HalfLytely®) included two 5 mg bisacodyl tablets and a 2 L solution of HalfLytely® containing 210 g PEG 3350, 2.86 g of sodium bicarbonate, 5.6 g of sodium chloride, 0.74 g of potassium chloride, and 1 g of flavoring ingredient (optional). The solution contains 31.3 mMole/L PEG, 65 mMole/L sodium, 53 mMole/L chloride, 17 mMole/L bicarbonate, and 5 mMole/L potassium.
B. Administration
[0062] In this single blind, active controlled study, the sulfate salt/PEG preparation or the bisacodyl/PEG preparation (HalfLytely®) kits were provided to 366 male and female outpatients that were at least 18 years of age and otherwise in good health requiring colonoscopy for routinely accepted indications. The order of preparation assignment was determined according to a computer generated randomization schedule. Patients self-administered the assigned study preparation in two amounts on the day before their scheduled colonoscopy.
[0063] Study patients were provided with a treatment questionnaire to record food consumption, any vomiting episodes and the date and time of preparation. Prior to the colonoscopy, study patients also completed a symptom questionnaire to report their overall experience with the preparation. Blood samples were collected at baseline and pre-colonoscopy for chemistry and hematology analysis.
[0064] The sulfate/PEG preparation was supplied as a kit containing one 6 ounce bottle of sulfate solution and one 2 L bottle of PEG-ELS. The bisacodyl/PEG preparation was supplied as a kit containing two 5 mg bisacodyl tablets and one 2 L bottle of PEG-ELS. The HalfLytely® and Bisacodyl Tablets Bowel Prep Kit (Braintree Laboratories, Inc.) was used as the control preparation.
[0065] All patients (both treatments) were instructed to consume clear liquids only on the day prior to colonoscopy. This clear liquid diet continued until after completion of the colonoscopy. For the sulfate salt/PEG group, starting at about 6:00 P.M. on the evening before colonoscopy, patients were instructed to pour the contents of the 6 ounce bottle of study preparation into the provided mixing cup and to fill the cup with water to the fill line (16 oz) and then drink the entire cup of solution. Patients were further instructed to drink one additional 16 ounce glass of water over the next two hours. Two hours after starting the first amount (approximately 8:00 P.M.), patients were instructed to begin drinking the 2 L of PEG-ELS solution at a rate of one 16 ounce glass every 20 minutes until the jug was empty. Patients were recommended to drink at least one additional 16 ounce glass of water on the evening prior to colonoscopy.
[0066] For the bisacodyl/PEG group, between approximately 12:00 P.M. and 3:00 P.M. on the day prior to colonoscopy, patients were instructed to take the two 5 mg bisacodyl tablets with water. After waiting for a bowel movement (or maximum of 6 hours after taking the bisacodyl tablets) patients were instructed to drink the 2 L HalfLytely® solution at a rate of 8 ounces every 10 minutes.
C. Measurements
[0067] Blinded study investigators rated the quality of each colonoscopy according to a four point scale ranging from “poor” to “excellent.” This scale is shown below in Table 4.
[0000]
TABLE 4
Colonoscopist Colon Cleansing Scores
Score
Grade
Description
1
Poor
Large amounts of fecal residue,
additional cleansing required
2
Fair
Enough feces or fluid to prevent a
completely reliable exam
3
Good
Small amounts of feces or fluid not
interfering with exam
4
Excellent
No more than small bits of adherent
feces/fluid
[0068] For the primary efficacy analysis, grades 3 and 4 were considered “successful” and grades 1 and 2 were considered “failures.” Each examination was also rated as to whether or not cleansing was adequate for examination and the need for re-preparation.
[0069] Safety assessments included adverse event monitoring as well as pre and post physical examination. Blood samples were collected at each study visit for chemistry and hematology analysis.
[0070] Patients completed a symptom questionnaire which asked them to provide an overall rating of their preparation related symptoms of stomach cramping, stomach bloating, nausea and overall discomfort.
D. Statistical Methods
[0071] Statistical Analysis Plan: The primary efficacy analysis was based upon a modified intent-to-treat (ITT) analysis and included all patients randomized that took any portion of study preparation. Patients that did not undergo colonoscopy because of inadequate preparation or preparation related adverse events were considered failures for the primary efficacy endpoint. However, patients that took study preparation but withdrew prior to colonoscopy for reasons unrelated to safety or efficacy were excluded from efficacy analyses. Patients that underwent colonoscopy had a determination of cleansing success based on the colonoscopists' score of cleansing (Table 4).
[0072] Success rate was analyzed using CMH Chi-square adjusting for the effect of investigator site. The formal hypothesis test result (p-value) for treatment difference is presented together with a two-sided 95% confidence interval for the difference. A lower CI bound greater than −15% will establish non-inferiority between BLI850 and HalfLytely® for a non-inferiority margin of 15%.
[0073] In addition, results are also presented using a non-inferiority test based upon the difference D=P 1−P2.
Null Hypothesis H0: P1−P2<=D0 versus Alternative Hypothesis H1: P1−P2=D1>D0, where P1 is the BLI850 group (treatment group) and P2 is the HalfLytely® group (reference or control group) and D0 is the acceptable margin of equivalence equal to an absolute margin of 15%.
[0075] Results of laboratory tests for the change from screening and group differences were tested using ANOVA. In addition, shift tables are presented to describe changes in lab parameter values between baseline and post-treatment time points using normal range categories (low, normal, high). A second analysis was performed by age subgroup (<65, ≧65, ≧75 years of age).
[0076] Symptom questionnaire data for patient reported individual symptoms for Overall Experience (nausea, stomach cramping, stomach bloating and overall discomfort) were tested using ANOVA with terms for treatment, site, and their interaction.
E. Results
[0077] 362 patients of the 366 patients that received their study preparation fully completed the study (defined as patients that had a colonoscopy). The primary efficacy analysis was based on 364 patients. All patients enrolled that took the study preparation and underwent colonoscopy (n=362) were included. Two patients were also included in the primary efficacy responder analyses as failures because they could not undergo colonoscopy due to a concurrent adverse event or non-compliance with preparation administration.
[0078] Patients reported to their study center for scheduled colonoscopy after completing their bowel preparation and returned study drug materials were reviewed for treatment compliance. A compliant patient was defined as one who returned no more than 4 ounces of the PEG-ELS solution, or who reported taking all solution. More HalfLytely® patients completed the entire preparation than BLI850 patients (94% to 87%, respectively, p=0.033), although compliance for both preparations was considered excellent.
[0079] Patient compliance with the study preparation administration was excellent, averaging more than 87%. Preparation time was significantly shorter for BLI850 patients, averaging 3.69 hours compared to 5.52 hours for HalfLytely® (p<0.001).
[0080] Table 5 includes the colonoscopy cleansing scores of all 364 patients that had a colonoscopy or withdrew due to safety or non-compliance. Sulfate salt/PEG achieved significantly more “Excellent” preparations than Bisacodyl/PEG (p=0.010). In addition, the average cleansing score was also significantly higher for sulfate salt/PEG.
[0000]
TABLE 5
Preparation Cleansing Score
Sulfate/PEG
Bisacodyl/PEG
Score
n (%)
n (%)
P 1,2
4
84
67
0.010
Excellent
(47.7%)
(35.6%)
3
74
90
Good
(42.0%)
(47.9%)
2
13
25
Fair
(7.4%)
(13.3%)
1
4
5
Poor
(2.3%)
(2.7%)
Missing
1
1
(0.6%)
(0.5%)
Mean Score 3
3.36
3.17
0.016
1 P-value comparing excellent preps is from a CMH, controlling for site;
2 P-value for mean score is from a one-way ANOVA with term for reatment.
3 05040 and 10003 were excluded as non-evaluable for efficacy analysis. 05006 and 06027 are included as “missing”
[0081] Sulfate salt/PEG patients had a higher percentage of successful preparations compared to bisacodyl/PEG patients (90% to 84%, respectively). Non-inferiority testing revealed a highly statistically significant result (p<0.001), supporting the hypothesis that same day preparation with sulfate salt/PEG is non-inferior to bisacodyl/PEG. Sulfate salt/PEG can be considered equivalent with respect to cleansing efficacy to the FDA approved bisacodyl/PEG control.
[0082] A sensitivity analysis of the primary endpoint using a true ITT population (all randomized subjects) confirms the previous conclusion that sulfate salt/PEG is non-inferior to bisacodyl/PEG, with 80.6% of sulfate salt/PEG ITT patients having a successful preparation compared to 79.3% of bisacodyl/PEG patients (p<0.001).
F. Adverse Side Effects
[0083] Patients rated their symptoms of cramping, stomach bloating, nausea and overall discomfort using a five point scale where a score of 1=“None,” 2=“Mild,” 3=“Bothersome,” 4=“Distressing,” and a score of 5=“Severely distressing.” Patients were instructed to rate these symptoms using the symptom questionnaire at Visit 2. Symptom data at their final visit are shown below in Table 6.
[0000]
TABLE 6
Mean Patient Symptom Ratings at Final Visit
Sulfate/PEG
Bisacodyl/PEG
Symptom 1
(n = 176)
(n = 190)
P 2
Cramping (SD)
1.50 (0.70)
1.55 (0.77)
0.393
Stomach Bloating (SD)
1.74 (0.87)
1.62 (0.82)
0.177
Nausea (SD)
1.70 (1.02)
1.65 (0.97)
0.818
Overall (SD)
2.06 (0.98)
1.76 (0.80)
0.032
1 1 = None; 2 = Mild; 3 = Bothersome; 4 = Distressing; 5 = Severely Distressing
2 p-value for difference between treatments by ANOVA
[0084] Patients generally had good experiences with both preparations as indicated by the low average symptom scores (most ranged between None (1) and Mild (2)). Although there was no difference between the preparations for symptoms of cramping, bloating and nausea, a very small but statistically significant difference in the general category “overall discomfort” (p=0.032) favoring Bisacodyl/PEG was observed. The difference represented +0.3 or less than one third of a unit score compared to Bisacodyl//PEG in the range between “None” to “Mild” and is considered clinically insignificant. The overall discomfort scores reported in this study are within the narrow range seen in previous studies of approved preparations.
G. Summary
[0085] Patients in the sulfate salt/PEG group had better cleansing, suitable for colonoscopy, relative to bisacodyl/PEG patients (90% vs. 84%, respectively). Furthermore, sulfate salt/PEG patients experienced significantly more “Excellent” preparations than bisacodyl/PEG (48% vs. 36%, respectively, p=0.010). Results from this study support the conclusion that same day preparation with sulfate salt/PEG is equivalent to same day preparation with bisacodyl/PEG with respect to preparation efficacy, and results in a greater number of “Excellent” preparations. Notably, the time to complete the method with successful results was shorter (about 3.69 hours) than to complete the Bisacodyl/PEG method.
Example 2
Clinical Evaluations
[0086] Blood samples of the patients taking part in the testing described above in Example 1 were analyzed at baseline and after preparation (just prior to colonoscopy). Table 7 shows means for each study visit as well as the change from baseline.
[0000]
TABLE 7
Mean (SD) Chemistry Values by Visit
ITT Population
Analyte
Normal
(units)
Range 1
Treatment
Baseline
Visit 2
Δ to Visit 2
p 2
Albumin
3.7-4.9
BLI-850*
4.48 (0.26)
4.51 (0.27)
0.03 (0.23)
0.161
(g/Dl)
HalfLytely ®**
4.51 (0.26)
4.50 (0.28)
−0.00 (0.22)
Alk Phos
40-135
BLI-850
72.1 (20.9)
73.0 (24.3)
1.46 (10.9)
0.716
(U/L)
HalfLytely ®
72.6 (26.2)
73.8 (29.5)
1.96 (13.6)
ALT
0-47
BLI-850
26.5 (19.1)
27.7 (18.1)
0.93 (8.8)
0.422
(U/L)
HalfLytely ®
26.9 (20.4)
31.1 (52.2)
4.20 (50.8)
Amylase
28-100
BLI-850
68.5 (26.2)
58.7 (22.3)
−11.1 (14.7)
0.486
(U/L)
HalfLytely ®
78.1 (93.0)
62.2 (33.0)
−16.5 (97.3)
Anion Gap
No Range
BLI-850
11.9 (2.05)
12.4 (2.10)
0.71 (2.70)
0.551
(mEq/L)
Available
HalfLytely ®
12.1 (2.02)
12.5 (2.29)
0.53 (2.79)
AST/SGOT
0-37
BLI-850
23.6 (8.9)
26.1 (11.6)
2.63 (6.5)
0.994
(U/L)
HalfLytely ®
24.0 (10.6)
26.4 (17.5)
2.61 (16.8)
Bicarbonate
20-31
BLI-850
25.0 (2.5)
24.3 (2.4)
−0.88 (2.6)
0.200
(mEq/L)
HalfLytely ®
24.9 (2.3)
24.4 (2.3)
−0.51 (2.5)
BUN
9-24
BLI-850
16.8 (5.1)
13.3 (4.7)
−3.08 (3.6)
0.222
(mg/dL)
HalfLytely ®
16.7 (6.8)
13.1 (6.0)
−3.59 (3.9)
Calcium
8.4-10.2
BLI-850
9.83 (0.39)
9.75 (0.41)
−0.08 (0.42)
0.271
(mg/dL)
HalfLytely ®
9.90 (0.45)
9.76 (0.40)
−0.13 (0.43)
Chloride
95-113
BLI-850
102.7 (2.6)
103.3 (2.6)
0.63 (2.4)
0.177
(mEq/L)
HalfLytely ®
102.7 (2.5)
103.1 (2.4)
0.27 (2.4)
Creatine
F 24-170
BLI-850
120.7 (111)
152.1 (220)
29.1 (198)
0.192
Kinase (U/L)
M 24-195
HalfLytely ®
116.2 (75)
124.4 (124)
6.2 (110)
Creatinine
F 0.5-1.0
BLI-850
0.97 (0.25)
0.97 (0.24)
0.00 (0.14)
0.127
(mg/dL)
M 0.6-1.4
HalfLytely ®
0.96 (0.35)
0.99 (0.37)
0.03 (0.12)
Direct
0.0-0.2
BLI-850
0.12 (0.05)
0.17 (0.06)
0.05 (0.05)
0.556
Bilirubin
HalfLytely ®
0.12 (0.05)
0.17 (0.08)
0.05 (0.06)
(mg/dL)
GFR
No Range
BLI-850
79.4 (19.5)
79.5 (21.2)
−0.21 (14.6)
0.072
Available
HalfLytely ®
82.1 (20.0)
79.3 (19.9)
−2.82 (11.5)
GGT (U/L)
F 0-33
BLI-850
36.4 (44.0)
34.2 (35.4)
−1.38 (11.8)
0.233
M 0-51
HalfLytely ®
34.0 (60.9)
31.0 (30.4)
0.73 (19.1)
Glucose
70-141
BLI-850
105.1 (28)
105.3 (31)
0.82 (32)
0.046
(mg/dL)
HalfLytely ®
107.4 (32)
100.4 (28)
−5.52 (25)
Magnesium
1.4-2.1
BLI-850
1.76 (0.15)
1.76 (0.15)
−0.01 (0.13)
0.105
(mEq/L)
HalfLytely ®
1.77 (0.15)
1.74 (0.14)
−0.03 (0.14)
Osmolality
275-295
BLI-850
288.5 (6.6)
287.3 (5.6)
−0.88 (6.2)
0.370
HalfLytely ®
288.1 (6.5)
287.8 (6.5)
−0.18 (7.9)
Phosphate
2.4-4.9
BLI-850
3.53 (0.59)
3.45 (0.56)
−0.08 (0.65)
0.390
(mg/dL)
HalfLytely ®
3.59 (0.55)
3.59 (0.55)
−0.02 (0.56)
Potassium
3.6-5.2
BLI-850
4.31 (0.47)
4.10 (0.39)
−0.19 (0.43)
0.344
(mEq/L)
HalfLytely ®
4.35 (0.46)
4.12 (0.38)
−0.24 (0.46)
Sodium
134-146
BLI-850
139.6 (2.4)
140.0 (2.3)
0.47 (2.2)
0.459
(mEq/L)
HalfLytely ®
139.7 (2.2)
140.0 (2.1)
0.29 (2.2)
Total
0.0-1.1
BLI-850
0.44 (0.22)
0.72 (0.32)
0.28 (0.21)
0.877
Bilirubin
HalfLytely ®
0.44 (0.21)
0.72 (0.35)
0.27 (0.24)
(mg/dL)
Total Protein
6.1-7.9
BLI-850
7.08 (0.37)
7.15 (0.44)
0.06 (0.38)
0.182
(g/dL)
HalfLytely ®
7.15 (0.44)
7.14 (0.44)
0.01 (0.36)
Uric Acid
F 2.2-6.4
BLI-850
5.50 (1.6)
5.82 (1.5)
0.39 (0.80)
0.231
(mg/dL)
M 3.1-8.8
HalfLytely ®
5.33 (1.4)
5.82 (1.3)
0.49 (0.77)
1 M = Male, F = Female;
2 P-Value for treatment differences is from a one-way ANOVA
*Sulfate salt/PEG prep described in Example 1
**Bisacodyl/HalfLytely ® prep described in Example 1
[0087] Mean glucose values (mg/dL) rose 0.8 in the sulfate salt/PEG group versus a decrease of 5.5 in the bisacodyl/PEG group. Creatinine values for sulfate salt/PEG patients did not increase from baseline to Visit 2, while creatinine values for bisacodyl/PEG patients increased slightly (+0.03).
[0088] Patients in both treatment groups had BUN decreases and bilirubin increases after preparation which was not considered to be clinically significant.
EQUIVALENTS
[0089] Those skilled in the art will recognize, or be able to ascertain, using no more than routine experimentation, numerous equivalents to the specific composition and procedures described herein. Such equivalents are considered to be within the scope of this invention, and are covered by the following claims. | Disclosed is a method for rapidly cleansing the intestines and colon of a patient by orally administering an aqueous hypertonic sulfate solution, and then an aqueous isotonic solution to induce purgation, the purgations induced resulting in intestinal and colonic cleansing in less than four hours from the administration of the sulfate solution. | 63,099 |
This application is a continuation of application Ser. No. 09/409,760 filed Sep. 30, 1999 (now U.S. Pat. No. 6,314,773) which is a continuation of application Ser. No. 08/985,901 filed Dec. 5, 1997 (now U.S. Pat. No. 5,960,655) which is a continuation of application Ser. No. 08/593,725 filed Jan. 29, 1996 (now U.S. Pat. No. 5,720,194), which is a division of application Ser. No. 08/371,319 filed Jan. 11, 1995 (now U.S. Pat. No. 5,487,290), which is a continuation of application Ser. No. 07/819,216 filed Jan. 13, 1992 (abandoned).
TECHNICAL FIELD OF THE INVENTION
This invention relates to a high security lock mechanism and, more particularly, to an electronically controlled combination lock and lock-bolt operable by a very small amount of self-generated electrical power.
BACKGROUND OF THE PRIOR ART
Items of extremely sensitive nature or very high proprietary value often must be stored securely in a safe or other containment device, with access to the items restricted to selected individuals given a predetermined combination code necessary to enable authorized unlocking thereof. It is essential to ensure against unauthorized unlocking of such safe containers by persons employing conventional safe-cracking techniques or sophisticated equipment for applying electrical or magnetic fields, high mechanical forces, or accelerations intended to manipulate elements of the locking mechanism to thereby open it.
Numerous locking mechanisms are known which employ various combinations of mechanical, electrical and magnetic elements both to ensure against unauthorized operation and to effect cooperative movements among the elements for authorized locking and unlocking operations.
One example of such recently-developed devices is disclosed in U.S. Pat. No. 4,684,945, to Sanderford, Jr., which relates to an electronic lock actuated by a predetermined input through a keyboard outside a safe to a programmable control unit within a housing of the safe. The device has an electric motor for driving a lock-bolt for locking a safe door to the safe housing, and means for displaying codes entered by the user, with a facility for selectively changing the necessary code. The device also has a battery-powered backup circuit maintained in a dormant state to conserve energy until an actuation key is operated. A microprocessor of the unit is programmed to activate a relatively high frequency of power output pulses at the start of movement of a locking bolt by the electric motor, to overcome inertia and any sticking forces on the bolt, and a lower frequency of power pulses to complete the movement of the bolt.
Another example is provided in U.S. Pat. No. 4,674,781, to Reece et al., which discloses an electric door lock actuator and mechanism having manual and electrically driven locking means. This device utilizes a combination of a lost motion coupling and resilient springs for driving a motive means to a neutral position, to thereby isolate an electric motor and gearing from the locking means so that the locking means may be operated manually without back-driving of the electric motor and intermediate gearing.
A major problem with such devices is that they require substantial amounts of electric power to perform their locking and unlocking functions. For securely storing and accessing highly sensitive or valuable items, it is important to avoid depending on the ready availability of sufficient electrical power for driving the locking mechanism. In fact, for many applications, the use of long-life batteries, even to power a small microprocessor, may also be deemed unacceptable.
The stringency of relevant U.S. government specifications is readily appreciated from Federal Specification FF-L2740, dated Oct. 12, 1989, titled “FEDERAL SPECIFICATION: LOCKS, COMBINATION” for the use of all federal agencies. Section 3.4.7, “Combination Redial”, for example, requires that once the lock-bolt has been extended to its locked position “it shall not be possible to reopen the lock without completely redialing the locked combination”, and defines the locked position as one in which the bolt has been fully extended. Section 3.6.1.3, “Emanation Analysis”, requires that the lock shall not emit any sounds or other signals which may be used to surreptitiously open the lock within a specified period. Section 4.5.2.2.4, “Surreptitious Entry”, requires that for any lock to be deemed acceptable, attempts shall be made to unlock the lock through manipulation, radiological analysis and emanations analysis, further including the use of computer enhancement techniques for signals or emanations. Even further, Section 6.3.2 defines surreptitious entry as a method of entry such as manipulation or radiological attack which would not be detectable during normal use or during inspection by a qualified person.
In short, for high security storage of sensitive or valuable material, in light of the availability of sophisticated computer-assisted means and methods for unauthorized operation of locking mechanisms, there exists a need for an autonomous locking mechanism that does not require batteries or external sources of power for any purpose, receives and recognizes only specific user-selected combination code information for access, emanates no information useful to persons attempting unauthorized operation, and is made to resist unauthorized operation even when subjected to strong externally imposed electrical, magnetic or mechanical forces, and satisfies other U.S. government specifications. Most important, once the mechanism is put in its locked position it loses all “memory” of the input combination code and requires a totally new and correct provision of the complete combination code to be unlocked again.
The present invention, as more fully disclosed hereinbelow, meets these perceived needs at reasonable cost with a geometrically compact, electrically autonomous, locking mechanism.
SUMMARY OF THE DISCLOSURE
It is an object of this invention to provide a locking mechanism which remains securely in a locked state until, following receipt of a predetermined combination code, a very small amount of electrical power is employed to put it in condition to be manually unlocked thereafter.
It is another object of this invention to provide a locking mechanism actuated by the input of a selected combination code followed by the delivery of a very small amount of electrical power generated during input of a user-selected combination code to a low friction engagement means to put the same in a position to enable purely manual unlocking of the mechanism thereafter.
Yet another object of this invention is to provide a locking mechanism which upon being put into a locked state remains in that state immune to electrical, magnetic, thermal or mechanical inputs accompanying attempts at unauthorized unlocking thereof.
It is an even further object of this invention to provide a secure locking mechanism which is unlocked by the provision of a preselected combination code within a specified time followed by the provision of a very small amount of electrical power to move an engagement element to a position to enable solely manual unlocking of the mechanism thereafter.
It is an even further object of this invention to provide a locking mechanism which utilizes a very small amount of electrical power, generated during input of a user-provided combination code, to be put into condition for manual unlocking, the mechanism, upon being manually put into a locked state, remaining in such a locked state until a predetermined combination code is entered.
These and other related objects are realized, according to a preferred embodiment of the invention, by providing a locking mechanism which comprises a first means for moving an engagement element from a disengaged position to an engageable position thereof solely upon receipt of a controlled predetermined electrical power output, a manually operated second means for engaging the engagement element when the latter is in its engageable position for thereby manually moving the first means further in a first direction and back in a second direction, and third means for driving a lock-bolt engaged by the further movement of the first means to drive the lock-bolt to locking and unlocking positions thereof in correspondence with movements of the first means in the first and second directions respectively. Movement of the first means in the second direction restores security by returning the engagement element to its disengaged position when the lock-bolt reaches its locked position.
In still another aspect of the invention, the first means comprises an electrical stepper motor having a rotor supporting the engagement element and having stable positions determined by magnetic detents which correspond to the disengaged and engageable positions of the engagement element.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an exemplary safe having a generally rectangular casing and a hinged door, with a lock mechanism according to this invention mounted to the door of the safe.
FIG. 2 is a horizontal cross-sectional view of the door and the lock mechanism at line II—II in FIG. 1 .
FIG. 3 is an exploded perspective view of a lock mechanism according to a preferred embodiment of this invention as viewed from a location behind a casing of the lock mechanism.
FIG. 4 is a vertical elevation view of elements of the lock mechanism which are mounted to a rear cover of a casing of a lock mechanism according to FIG. 3 .
FIG. 5 is a plan view of the elements illustrated in FIG. 4 in the direction of arrow V therein.
FIGS. 6A, 6 B and 6 C are elevation views of elements of the lock mechanism operationally supported to and within the casing of the lock mechanism of FIG. 3 to explain coaction of the elements at various stages as the lock-bolt is moved to an unlocked disposition thereof.
FIGS. 7A, 7 B and 7 C are vertical elevation views illustrating, for a second embodiment of this invention, how various elements of the invention coact at various stages as the lock-bolt is moved from its locked position to its unlocked position.
FIGS. 8A, 8 B and 8 C are elevation views, according to a third embodiment of this invention, illustrating various stages in the movement of the lock-bolt thereof from its locked to its unlocked position.
FIG. 9 is a partial vertical cross-sectional view of one embodiment of another aspect of this invention, in which a voice coil is employed to ensure against unauthorized magnetically induced unlocking of the mechanism.
FIG. 10 is a partial vertical cross-sectional view of another embodiment of the aspect shown in FIG. 9 . FIG. 10A is a vertical cross-sectional view at section XI—XI in FIG. 10 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A typical safe for securely storing valuable items, e.g., sensitive documents, precious jewelry or cash, hazardous materials such as radioactive or biologically dangerous substances, and the like, conveniently has a generally cubical form, with an opening closable by a single hinged door. Such a safe also typically has a multi-walled construction, both for the principal sides and for the door. As best seen in FIG. 1, such a safe 100 generally has a principal side wall 102 to which a door 104 is locked by operation of a lock mechanism 200 .
As best seen in FIG. 2, a lock mechanism 200 according to a preferred embodiment of this invention has an external user-accessible hub 202 conveniently provided with an easily viewable combination code input display window 204 and a manually rotatable combination input knob 206 . Hub 202 is attached to the outer surface 106 of door 104 in any known manner. Similarly, a casing 208 is securely attached to an inside surface 108 of door 104 in known manner. Door 104 may be kept hollow or may have an inner space filled with a thermally insulating material (not shown) to protect the contents of the safe in the event of a local fire.
A shaft 210 , rotatable by knob 206 , extends through the thickness of door 104 and into casing 208 to cooperate thereat with a combination of important elements of the present invention as described more fully hereinbelow. A lock-bolt 212 is slidably supported by casing 208 to an unlocking position, upon appropriate manual operation of combination-input-knob 206 by a user. Casing 208 is provided with a detachable cover 272 which also serves to provide support to various components of the lock mechanism according to this invention.
FIG. 3 is an exploded view of a lock mechanism according to a preferred embodiment of this invention, as viewed in looking toward the inside surface 108 of door 104 . Persons of ordinary skill in the art can be expected to appreciate that it is not critical to the utility of the present invention that lock mechanism 200 be mounted to a door since, without difficulty, the lock mechanism can be easily mounted to a wall of safe 100 in such a manner that lock-bolt 212 projects in its locking position into the safe door to lock it to the body of the safe. Details of such an alternative construction are simple and easy to visualize, hence illustrations thereof are not included. Such structurally obvious variations are contemplated as being within the scope of this invention.
Referring again to FIG. 3, an aperture 110 extends through the entire thickness of door 104 to closely accommodate therein shaft 210 extending from combination-input knob 206 into a space 214 defined inside casing 208 . Located in correspondence with aperture 110 in door 104 , in casing 208 there is provided an annular journal bearing 216 to closely receive and rotatably support shaft 210 via 266 projecting therethrough into space 214 .
Casing 208 is conveniently formed, e.g., by machining, molding or otherwise in known manner, to provide a pair of guide slots 218 , 218 which are shaped, sized and disposed to closely accommodate lock-bolt 212 in a sliding motion between its locked and unlocked positions. While an important object of this invention is to provide its locking function in a highly compact manner, which inherently necessitates the selection of strong materials for forming the casing 208 and lock-bolt 212 , guides 218 , 218 and lock-bolt 212 must be shaped and sized to provide the necessary strength to resist any foreseeable brute-force to open door 104 . Persons of ordinary skill in the art are expected to know of suitable materials for such purposes. For example, although the safe walls and door may be made of highly tempered steel or alloy, the lock bolt itself may be made of a softer metal such as brass or an alloy such as “ZAMAK,” and so may other elements of the mechanism.
As also illustrated in FIG. 3, within space 214 inside casing 208 there are also provided attachment points for biasing means such as springs 222 , 222 to be employed as discussed hereinbelow. In the embodiment illustrated in FIG. 3, there are also provided at an inside surface of casing 208 a small reed switch 224 and a socket 226 disposed to enable push-in electrical connection of a plurality of electrical connector pins 282 which are best seen in FIG. 5 . Also provided on a wall surface of casing 208 near biasing springs 222 , 222 is a guide pin 228 which closely fits into an elongate parallel-sided aperture 230 in the sliding element 232 which is generally flat and slides along an inner surface of casing 208 . Sliding element 232 is provided with a pair of spring-engaging pins 234 , 234 which engage with biasing springs 222 , 222 , whereby sliding element 232 is biased in a preferred direction, an upward direction in the illustration per FIG. 3 .
Note that sliding element 232 is also provided with a cam-engaging pin 236 , at least one elongate straight side 238 which may be used in known manner to provide additional sliding guidance, one or more weight-reducing apertures such as 242 which may also be shaped to perform cam functions, a circular aperture 244 close to cam-engaging pin 236 , and a cam-notch 246 at the end of sliding element 232 opposite the end closest to cam-engaging pin 236 .
Lock-bolt 212 , as best seen in FIG. 3, is provided with a pivot-mounting aperture 248 into which is mounted a pivot 250 , to pivotably connect a lever arm 252 to lock-bolt 212 to communicate a manual force for moving the lock-bolt, guided by guides 218 , 218 , between its locked and unlocked positions.
Lever arm 252 is provided with a lateral pin 254 which is disposed to be engaged by cam-notch 246 of sliding element 232 so as to be forcibly moved thereby, in a manner to be described more fully hereinbelow, when sliding element 232 is itself caused to be slidingly moved as guided by the coaction of guide pin 228 and the parallel sides of elongate aperture 230 . The distal portion of lever arm 252 extending beyond the location of lateral pin 254 is formed as a hook 256 , the shape of which is provided with an outside edge having a plurality of contiguous portions 258 , 260 and 262 which coact with a downwardly depending fixed cam portion 264 formed at an inside surface of casing 208 . This coaction, at different stages in the course of moving lock-bolt 212 between its locked and unlocked positions, is best understood with successive reference to FIGS. 6A, 6 B and 6 C and is described more fully hereinbelow.
An end portion of shaft 210 which extends into space 214 preferably has a square cross-section, to which is mounted a rotary element 266 via a matchingly shaped and sized central fitting aperture 268 , as best seen in FIG. 3 . Accordingly, when a user of the safe manually applies a torque to the combination-input knob 206 (see FIG. 2 ), he or she transmits the torque to shaft 210 to thereby forcibly rotate rotary element 266 . A split ring 270 , for example, may be utilized to retain the rotary element 266 to shaft 210 in known manner. Other known techniques or structures may be used, instead of such a split ring, for such retention. By this arrangement, there is readily available, through rotary element 266 , a manually provided torque at a point inside space 214 of casing 208 , i.e., within the secure containment space inside safe 100 , even when door 104 is locked. This is a feature essentially common to the various embodiments disclosed and claimed herein. The exact structural form of the manually-torqued rotary element is different, and is somewhat differently utilized, in the various embodiments.
In the best mode of this invention, exemplified by the preferred embodiment illustrated in exploded view in FIG. 3, rotary element 266 , in a portion closest to an inside surface of cover 272 of casing 208 , is provided an internal ring gear 274 . Outwardly of ring gear 274 , there is provided a periphery having a toothed arcuate portion 276 , a smooth circumferential portion 278 and a radially relieved smooth circular portion 280 .
At a side of rotary element 266 between internal ring gear 274 and annular journal bearing 216 is a circular cam portion 400 provided with a radially-relieved mechanical detent 402 shaped and sized to receive hook 256 when lever arm 252 is pivoted to a predetermined degree about pivot 250 by a sliding movement of sliding element 232 and a corresponding coaction between lateral pin 254 of lever arm 252 and cam notch 246 of sliding element 232 . A small magnet 245 is mounted to rotary element 266 , at a predetermined angular disposition vis-a-vis mechanical detent 402 , at a radius such that it passes by reed switch 224 to activate it under conditions selected by microprocessor 288 as described hereinafter.
As best seen in FIG. 4, cover 272 on the side facing space 214 of casing 208 supports a plurally-pinned electrical plug element with pins 282 located to be electrically engageable with socket 226 , an electrical power generator 284 , a power storage capacitor 286 , a microprocessor 288 , and assorted wiring 290 forming part of an electrical circuit. Details of this electrical circuit and various aspects of its functions, e.g., how a predetermined combination code may be provided to and stored in microprocessor 288 , how segments of a selected combination code are displayed in window 204 as they are input by a user operating manually rotatable combination-input knob 206 , and the like, are disclosed in U.S. Pat. No. 5,061,923, which is expressly incorporated herein by reference for all such relevant disclosure therein.
Cover 272 , as best seen in FIG. 3, is provided with countersunk apertures 292 and one or more location-indexing projections 294 to facilitate precise fitting of cover 272 with casing 208 and secure affixation therebetween by screws 296 . When cover 272 is thus indexed and affixed to casing 208 , a sun-and-planet gear train 298 , best seen in FIG. 4, meshes with internal ring gear 274 of rotary element 266 to be rotated thereby, plug element 282 fits to socket 226 , and lock-bolt 212 then is slidably movable in a closely fitting aperture of closed casing 208 .
As described in, detail in U.S. Pat. No. 5,061,923, incorporated herein by reference for such details, such affixation of cover 272 to casing 208 , upon manual rotation of combination-input knob 206 , causes rotation of shaft 210 and rotary element 266 mounted thereto, resulting in manual rotation of planetary gear train 298 to generate electrical power in electrical generator 284 . Some of this electrical power is conveyed via a plurality of fine wires (not illustrated) which are disposed along shaft 210 , to provide a liquid crystal display of numbers relating to a combination code in display window 204 . A portion of the power generated by electrical power generator 284 , under the control of microprocessor 288 , is stored in power storage capacitor 286 . Some of this stored electrical power is thereafter available for a period of time under the control of microprocessor 288 , upon determination thereby that a correct combination code has been provided by a user, to perform a vital function of the present invention. This vital function is to create such a coaction of the above-described elements that lock-bolt 212 is positively and controllably moved, solely by a manually-provided force, from its locked position to its unlocked position.
In the best mode of this invention, as best understood with reference to FIG. 3, there is a very low-friction rotary, electric motor 300 provided with magnet detents symbolized by the reference character “D” in the figure, which give a rotor 302 at least two stable positions which are angularly separated with respect to an axis of the rotor by a predetermined angle, preferably approximately 36°. Such motors are known; one example is a Seiko model. Hence, detailed illustrations of the internal structure of motor 300 , etc., are not believed necessary for an understanding of the structure or specific functioning of the present invention in any of the embodiments disclosed and claimed herein.
What is of particular importance is that motor 300 is electrically connected by a portion of circuit wiring 290 so as to be able to receive from power storage capacitor 286 at least one predetermined small pulse of electric power at a time controlled by microprocessor 288 . Microprocessor 288 is initially provided a user-input reference combination code which, thereafter, serves as reference data until and unless it is replaced or changed as is fully described in copending application U.S. Ser. No. 07/250,918, incorporated herein by reference for relevant details disclosed therein. Subsequently, when a user rotates combination-input knob 206 to actuate the lock mechanism, rotation of shaft 210 (regardless of direction of its sense of rotation), generates electrical power to display elements of the combination code as they are being input and, simultaneously, enables the storage of a quantity of power in power storage capacitor 286 . Then, upon microprocessor 288 recognizing that a correct combination code has been provided, e.g., upon receipt of a predetermined ordered set of three numbers, a portion of the power stored in power storage capacitor 286 is released to motor 300 when further rotation of rotary element 266 in a predetermined direction next brings magnet 245 close enough to reed switch 244 to actuate it. Alternatively, power can be supplied to the motor 300 by a separate capacitor (not shown).
This motor 300 has very low-friction bearings rotatably supporting rotor 203 , preferably with no grease, oil or other lubricant being utilized therein to avoid deterioration thereof over prolonged period of time. The coaction of ring gear 274 and gear train 298 generates sufficient electrical power during the process of inputting the requisite combination code to enable power storage capacitor 286 to store and deliver an adequate electrical power pulse (or more than one pulse, as needed) to cause rotor 302 to move from a stable disengaged position corresponding to a first magnetic detent to a stable engageable position corresponding to a second magnetic detent thereof. Motor 300 thus functions as a transducer in which a small amount of received electrical power is converted, i.e., transduced, to a small mechanical rotation of rotor 302 .
A variation of this arrangement can be realized using simple modifications to the circuitry, so that power to actuate the motor 300 is provided directly from power generation elements to the motor without first storing that quantity of electrical charge in one or more capacitors. Power to operate the microprocessor, however, may still be stored in and provided through one or more capacitors.
As best seen in FIG. 6A, rotor 302 has an arcuately relieved portion 304 disposed to be closest to and accommodating of the outer peripheral portion 276 of rotary element 266 when rotor 302 is in its disengaged position. In the best mode illustrated in FIGS. 6A-6C, a peripheral arcuate portion 306 of rotor 302 is provided with a plurality of teeth shaped and sized to be positively engageable with the teeth of toothed outer peripheral portion 276 of rotor element 266 . Upon the provision of the requisite electric power pulse from power storage capacitor 286 , as previously described, rotor 302 promptly rotates to its stable engageable position, this being one in which its toothed outer portion 306 is rotated to become engageable by teeth of peripherally toothed portion 276 of rotary element 266 , i.e., when rotary element 266 is turned counterclockwise in FIGS. 6A, 6 B and 6 C to engage said teeth of portion 276 with the teeth of rotor 302 .
Once such an engagement is initiated, further manual rotation of rotary element 266 , due to manual torque provided by a user rotating combination-input knob 206 , rotor 302 is forcibly and positively rotated in a rotational direction opposite to that of shaft 210 . In other words, simply by the provision of a very small electrical power pulse, which is preferably in the range of only a few microwatts, rotor 302 becomes drivable solely by the manual rotary input under the control of the user, and this occurs only after the input of a correct combination code as recognized by microprocessor 288 with reference to its prestored reference combination code data.
Rotor 302 , as best seen in FIG. 6A, in a face thereof closest to sliding element 232 , has two arcuate, diametrally opposed, generally kidney-shaped openings 308 , 308 . These recesses are shaped and sized to non-bindingly receive therein a pair of drive pins 310 , 310 provided on a rotatable cam element 312 which is mounted to be freely rotatable about the same axis as rotor 302 within angular limits imposed by arcuate recesses 308 coacting with drive pins 310 . In other words, drive pins 310 , when disposed to be located near corresponding ends of arcuate recesses 308 while rotor 302 is in its disengaged position, remain unmoved while the aforementioned electric power pulse causes rotor 302 to rotate to its stable engageable position, at which point drive pins 310 are located at the corresponding opposite ends of their respective recesses 308 , 308 . Note that this ensures that with only a few microwatts of power, rotor 302 rotates from its disengaged position to its engageable position. This is an important aspect of the present invention and is common to all disclosed embodiments. However, upon further manually forced rotation of rotor 302 , arcuate recesses 308 , 308 each forcibly engage with corresponding drive pins 310 , 310 to forcibly rotate rotatable cam element 312 . Rotatable cam element 312 is located so as to then, and only then, force a portion of its outer peripheral edge into contact with cam-engaging pin 236 of sliding element 232 .
In this manner, further solely manual rotation of rotatable cam 312 will generate a forced sliding motion of sliding element 232 , as guided by guide pin 228 engaging with elongate aperture 230 , by overcoming of a biasing force provided by bias springs 222 , 222 . In the structure as illustrated in FIGS. 1 and 6 A- 6 C the sliding element 232 thus is manually moved downward.
As previously noted, cam notch 246 at the upper distal end of sliding element 232 engages with lateral pin 254 of lever arm 252 . Thus, as best understood with reference to FIGS. 6A, 66 and 6 C, as sliding element 232 is forced downward, cam notch 246 thereof applies a downward pull on the hooked end of lever arm 252 to correspondingly pull hook 256 thereof downwardly toward a mechanical detent 402 provided on rotary element 266 . In the illustrations per FIGS. 6A, 6 B and 60 , as lever arm 252 is drawn downward to engage with mechanical detent 402 , edge portion 260 thereof coacts with a sloping edge of fixed cam portion 264 to be further moved downward into a positive engagement with mechanical detent 402 . Thus, as best seen with reference to FIG. 6B, the downward motion of sliding element 232 , contact between the sloping edge of fixed cam portion 264 and the outside edge portions 258 , 260 and 262 of lever arm 252 , and the eventual engagement of hook 256 with mechanical detent 402 of rotary element 266 all, eventually, lead to a manually-provided force being transmitted by lever 252 , through pivot 250 , to forcibly draw lock-bolt 212 into casing 208 . Ultimately, lock-bolt 212 becomes substantially drawn into casing 208 to its unlocked position.
Also, as best understood with reference to FIG. 6C, when this state of affairs is reached, lever arm 252 can rotate no further about pivot 250 because it is then in forced contact with the radially outermost portions of the detented side of rotary element 266 . Therefore, once lever arm 252 is engaged with rotary element 266 to draw lock-bolt 212 to its unlocked position, further forced rotation of combination-input knob 206 is prevented. Under these circumstances, door 104 may be opened and access may be had by the user to the contents of safe 100 .
Once the user has completed his or her business with the contents of the safe, door 104 may be put in a position to close safe 100 and the combination-input knob 206 rotated in the opposite sense, i.e., in a direction opposite to that which enabled lock-bolt 212 to be manually moved to its unlocked position. As best understood with reference to FIG. 6A, as the relieved detent portion of rotary element 266 is thus rotated, coaction between the same and the outer edge portion 262 of lever arm 252 forces lever arm 252 upward and in a direction that will drive lock-bolt 212 out of casing 208 toward a locked position. In this process, as the distal end of lever arm 252 slips past fixed cam portion 264 of casing 208 , lateral pin 254 of lever arm 252 is placed into engagement with cam notch 246 and serves to move sliding element upward while the biasing force provided by springs 222 also acts upward on sliding element 232 . At the same time, as rotating element 266 rotates, the meshed teeth of peripheral portion 276 of rotating element 266 and the teeth of toothed portion 306 of rotor 302 move in engagement until rotor 302 is rotated to such an extent that arcuate relieved portion 304 thereof abuts the relieved portion of the periphery of rotary element 266 .
Again, as best seen with reference to FIG. 6A, this united action of the above-described elements is such that when sliding bolt 212 eventually reaches its locked position, rotor 302 is returned to its stable disengaged position and will, thereafter, be retained there by the corresponding magnetic detent of motor 300 .
Note that the rotation of rotary element 266 required to thus project lock-bolt 212 out of casing 208 into a locked position is minimal, and that very little electrical power is generated as an incident thereto. Consequently, the electrically discharged circuit does not acquire sufficient stored electrical charge to be able to influence stepper motor 300 while lock-bolt 212 moves from its unlocked to its locked position. A very important consequence of this, in the context of the present invention, is that the entire lock mechanism becomes totally deactivated upon lock-bolt 212 reaching its locked position. Once this happens, lock-bolt 212 can not be moved to its unlocked position without the provision of the correct and entire combination code which must be found satisfactory by microprocessor 288 to enable the unlocking process as described hereinabove. In short, once the door is locked, the only way to unlock it is to correctly provide the entire combination code.
The basic concept of this invention, as realized in the preferred embodiment described hereinabove, may also be practiced with other embodiments. One such embodiment 700 is illustrated, in various operational stages, in FIGS. 7A-7C. A detailed description of this second embodiment follows.
Referring to FIGS. 7A-7C, a view intended to be generally comparable to the view of the first embodiment, per FIG. 6A, a lock-bolt 212 is slidably guided within guides 218 , 218 and a pivot 250 pivotably connects lock-bolt 212 to a lever arm 702 which has a hook 704 at a distal end thereof. The extreme distal end of lever arm 702 ends in a frontal surface 706 , the shape of hook 704 being defined by an elongate curved surface 708 which meets a rear hook surface 710 at a point 712 of the hook. These surfaces are polished smooth. Lever arm 702 , at a point intermediate its ends, is provided with a spring connection pin 714 . A first spring 716 , of selected length and stiffness, is hooked at one end to spring connection pin 714 and at another end to a first spring attachment point 718 at an upper portion of lock casing 208 . Absent the application of an externally applied force, first spring 716 provides a sufficient biasing force to hold lever arm 702 with its smooth front surface 706 in contact with a matchingly inclined face of fixed cam 264 formed as part of casing 208 .
In this second embodiment, as in the first embodiment illustrated in FIGS. 3-6C, there is provided a shaft 210 rotated by a user manually operating combination-input knob 206 , as will be understood by reference to FIG. 2 . Keyed to rotate with shaft 210 is a rotary cam element 720 which has an outer diameter such that when lever arm 702 is in its uppermost position, point 712 of hook 704 clears the circumferential rim of rotary cam element 720 . In this circumferential periphery, there is provided a generally triangular detent 722 having inclined sides forming a vertex directed toward a rotational axis of rotary cam element 720 , as best understood with reference to FIGS. 7A-7C. Rotary cam element 720 is also provided with a hook-engaging detent 724 formed and shaped to be able to accommodate hook 704 of lever arm 702 under conditions described hereinafter.
A low-friction, low-power, electric motor 300 is provided to receive a controlled electrical power pulse under the same conditions and in substantially the same manner as was described in detail for the first embodiment. Rotation of shaft 210 by a user, through a sun and gear train mounted on shaft 210 , will generate and store some electrical power under the control of a microprocessor. Upon satisfactory reception of a correct combination code input from a user, the microprocessor will release from an electrical storage capacitor a small controlled pulse of electrical power to cause a rotor of electric motor 300 to rotate from a first stable “disengaged” position to a second stable “engageable” position, these positions being defined by corresponding magnetic detents. For the sake of conciseness, a detailed description is not repeated herein of the manner in which the electrical power is generated and how, upon being provided the correct combination code input the microprocessor provides the necessary small electrical power pulse to motor 300 to cause the rotor thereof to turn. These details are believed to be comprehensible to a person of ordinary skill in the art upon a study of the earlier provided detailed description.
In the second embodiment 700 , as best seen in FIGS. 7A-7C, the rotor of electric motor 300 is provided with a generally radially extending engagement lever 726 and a radially eccentric elastic cam element 701 . Engagement lever 726 and eccentric cam 701 are thus mounted to be rotatable with the rotor (not expressly shown) of motor 300 . When the rotor of motor 300 is in its disengaged position, eccentric cam 701 has its periphery close to but not in contact with the circumferential periphery of rotary cam element 720 and the distal end of engagement lever 726 is located away therefrom. However, reception of the predetermined small electrical power pulse by motor 300 , (clockwise in FIGS. 7A-7C) causes eccentric cam 701 to contact the periphery of rotary cam element 720 . Frictional force thus generated causes the rotor to be turned manually thereafter, and engagement lever 726 is thus positively moved to extend into triangular detent 722 . Continued manual rotation of the rotary cam element 720 thereafter forcibly and manually rotates the rotor of motor 300 .
It will be recalled that the location of a small magnet on the rotary element of the first embodiment actuates a reed switch 224 when the rotary element 266 turned to a predetermined position after reception by the microprocessor of a correct and complete combination input signal. For the sake of conciseness and clarity the details of such operation are not repeated and such elements are not illustrated in FIGS. 7A-7C, but it will be understood that such components are present and cooperate in the manner previously described. Thus, upon reception of a complete and correct combination input by the microprocessor in the second embodiment, motor 300 receives the required small electrical power pulse and rotates its rotor so that the distal end of engagement lever 726 , assists by movement of the elastic eccentric cam 701 caused by the power pulse to the motor 300 and subsequent rotor rotation friction between the elastic eccentric cam 701 and the contacting periphery of rotary cam element 720 permitting rotation of the rotary cam element 720 , rotates into triangular detent 722 of manually rotated rotary cam element 720 .
As was the case in the first embodiment, there is provided a rotatable element (not shown in FIGS. 7A-7C, but similar to 312 in FIG. 3) mounted to rotate freely about the axis of motor 300 . Thus, when motor 300 has rotated its rotor by a predetermined small amount after receiving the small electrical pulse, the rotatable cam element 312 engages, and rotates a radial arm ending in a transverse cam pin 728 . See FIGS. 7A-7C. Rotation of cam pin 728 about the axis of the motor is thus obtained by the application of a manual torque by coaction of the rotary cam element 720 and engagement lever 726 engaged therewith.
A second spring 730 is engaged at one end to spring connection pin 714 of lever arm 702 and has a second end disposed to be pulled by cam pin 728 . The length of second spring 730 is selected such that it is put under tension only after engagement of engagement lever 726 by detent 722 of rotary cam element 720 as described in the immediately preceding paragraphs. Until that happens, second spring 730 is not subjected to any external force. However, once cam pin 728 is manually moved, as described above, it turns about the axis of motor 300 to a point where it begins to exert a force along second spring 730 and this force is to spring connection pin 714 of lever arm 752 . This force, manually provided, is sufficient to overcome the biasing force of first spring 716 , and eventually draws lever arm 702 to be drawn forcibly to thereby draw lock bolt 212 from its locking position to its unlocking position (as best seen in FIG. 7 C).
The second embodiment thus operates in the manner just described in accordance with the same basic principles as were earlier described with reference to the first embodiment.
When the user wishes to lock the mechanism, he or she simply needs to turn combination-input knob 206 , and thus shaft 210 and rotary cam element 720 , in a clockwise direction as would be seen with reference to FIG. 7C, i.e., in a direction contrary to that in which it was turned to bring lock bolt 212 into its unlocking position. When this is done, forcible co-action between the profiled hook engaging detent 724 and the elongate curved leading face 708 of hook 704 causes lever arm 702 to rotate about pivot 250 while applying a manually provided force to drive lock bolt 212 to its locking position. Eventually, when rotary cam element 720 has rotated sufficiently, co-action between triangular detent 722 and engagement lever 726 will cause the tension force in second spring 730 to be relieved and the rotor of motor 300 will return to its disengaged position as controlled by the corresponding magnetic detent. Once this is accomplished, the biasing force provided by first spring 716 will return lever arm 702 to the position best seen in FIG. 7 A. Since hook 704 is then no longer in contact with rotary cam element 720 at this time, any unauthorized rotation of shaft 210 will not succeed in unlocking the locking mechanism. Only the provision of a complete and correct combination code input can thereafter reactuate the mechanism and cause it to move to its unlocking position. There is, thus, provided an alternative simple structure for a locking mechanism.
The third embodiment 800 , operating to the same basic principles, is illustrated in FIGS. 8A-8C. In this embodiment, the elements for generating electrical power and controlling its delivery to motor 300 are as previously described. Lock bolt 212 is slidingly guided in guides 218 , 218 as before. Lever arm 802 is pivotable about pivot 250 and has, as in second embodiment 700 , a hook 804 at a distal end. A rotary cam element 806 is manually rotatable by affixation to shaft 210 . Rotary cam element 806 has a hook-engaging profiled detent 808 , with an otherwise smooth circumferential periphery 810 smoothly contiguous therewith.
The rotor of electric motor 300 has a gear wheel 812 the teeth of which are continuously engaged with the teeth of an arcuate toothed sector 814 of an element 816 pivotably mounted at a pivot 818 attached to an inside surface of casing 208 . Element 816 , on the side opposite to toothed sector 814 , has a sideways extension 820 having a generally triangular internal opening 822 and an external edge surface cam comprising a first straight portion 824 , an obtuse angle 826 , a short external edge portion 828 , a substantially right angled corner 830 , and a second straight edge portion 832 , as illustrated in FIGS. 8A-8C.
Lever arm 802 has a spring connection point 834 , a short rotatable arm 836 pivotably mounted on a pivot 838 and a stop pin 840 against which short rotatable arm 836 rests under a biasing force provided by a spring 842 .
As illustrated in FIG. 8A, when lock bolt 212 is in its locking position, i.e., projecting outwardly of casing 208 , lever arm 802 has its distal end and hook 804 in their uppermost position, with hook 804 barely touching the smooth circumferential periphery 810 of rotary element 806 . At this time, a cam pin 844 , extending transversely of short rotatable arm 836 near an end opposite to an end attached to spring 842 , is close to but not contacting the cam surface edge of element 816 at obtuse angle 826 thereof. See FIG. 8 A.
When a user inputs the correct and complete combination code, as with the previously discussed embodiments, a microprocessor acts in combination with the reed switch and a magnet (not shown) mounted to the rotary element 806 in the manner previously described with respect to the other embodiments. A small electrical power pulse is then provided to electric motor 300 when hook-engaging detent 808 is at a predetermined position with respect to hook 804 . Pivotably supported element 816 is very light in weight, therefore has a small mass inertia, and is supported at pivot 818 with very little friction, preferably without the use of lubricants that could deteriorate over time. It is also intended to be balanced about pivot 818 so that, even with a very small electrical power pulse, motor 300 can turn gear wheel 812 and, thereby, element 816 . At this time, in the disposition illustrated in FIG. 8A, a lever arm cam pin 846 is at a first corner of opening 822 of element 816 .
Upon receiving the small electrical pulse, motor 300 causes rotation of its rotor and gear wheel 812 mounted thereto, and toothed sector 814 engaged therewith causes rotation of element 816 in a clockwise direction, preferably by about 30°, as illustrated in FIGS. 8A-8C. The short cam surface edge portion 828 then slips away from under cam pin 844 , lever arm cam pin 846 coacts with an inside edge of triangular opening 822 to pivot lever arm 804 about pivot 250 so that hook 804 can then make contact against circumferential periphery 810 .
Eventually, as rotary cam element 806 is manually turned counterclockwise, hook 804 enters hook-engaging detent 808 of manually rotated rotary element 806 . Once this occurs, further counterclockwise manual rotation of rotary element 806 forcibly pulls lever arm 802 leftward, and thus lock bolt 212 slides into casing 208 . An uppermost outer edge of the hooked distal end of lever arm 802 slips under fixed cam 264 provided at an upper portion of casing 208 . The dimensions of the various elements are selected so that when lock bolt 212 has reached its “unlocking” position detent 808 , the hook engaging detent 808 cannot pull on lever arm 802 any further, as best understood with reference to FIG. 8 C. The locking mechanism is now in its unlocked state.
Note that, as with the two previously described embodiments, in this third embodiment the basic principle utilized is to employ a very small electrical power pulse to cause a light-weight, low-friction electric motor to cause a small rotatable element to rotate to initiate an engagement between a lever arm and a manually driven rotatable rotary element to enable delivery of a manual force to drive lock bolt 212 from its locking to its unlocking position. Note also that, as with the previous embodiments, such an engagement becomes possible only after the microprocessor has received a correct and complete combination code input from the user, and only when the user manually torques rotary element 806 thereafter.
In order to put the locking mechanism in its locking state, the user must manually rotate rotary element 806 in the contrary direction, i.e., clockwise in FIG. 8 C. Co-action between the smooth, curved, outer edge of hook 804 and hook-engaging detent 808 will then cause a manually provided force to drive lock bolt 212 to its locking position rightward and, at the same time, once cam pin 844 contacts the second straight edge portion 832 , element 816 will be caused to also rotate in a clockwise manner under a bias force conveyed from spring 842 . Due to the engagement between toothed sector 814 and gear wheel 812 of motor 300 , the motor also is thus returned to its disengaged detent-controlled position. At this time, under the urging of spring 842 acting on rotatable arm 836 , cam pin 844 will again return to its location inside obtuse angle 826 of the cam surface edge of element 816 . Rotary element 806 will have rotated so that its smooth outer circumferential periphery is now immediately adjacent hook 804 .
Further uncontrolled, e.g., unauthorized, rotation of shaft 210 and rotary element 806 will not cause a lock-opening engagement between hook 804 and hook-engaging detent 808 until and unless element 816 is again caused to rotate out of the way of cam pin 844 , this being possible only under the control of the microprocessor after the microprocessor receives a correct and complete combination code input. The lock is thus safe from unauthorized opening once lock bolt 212 is put in its “locking” position, i.e., once it is extended outwardly of casing 208 as best illustrated in FIG. 8 A.
As will be appreciated, to ensure against forcible or clever attempts at unauthorized unlocking operation of the locking mechanism, additional security elements may be provided. Two embodiments of such an aspect of an improving addition to the above-described invention are illustrated in FIGS. 9, 10 and 10 A, as described more fully hereinbelow.
FIG. 9 illustrates a mechanism that can act in combination with any of the above-described embodiments to further ensure against attempts at unauthorized operation of the locking mechanism by the imposition of an external magnetic field.
This security device 900 preferably has its principal components disposed within a common casing 902 shared with the electrical windings 904 and rotor 906 of the electrical motor (otherwise used in the same manner as electric motor 300 of the previous embodiments). Rotor 906 is supported on an axle 908 mounted in low friction bearings (not shown) and has an external gear wheel 910 which mechanically coacts with other elements as previously described.
At the inside end of rotor 906 , within casing 902 , there is provided a blocking member formed as a non-magnetic disk 912 which clears the inside surface of casing 902 and is rotatable with rotor 906 and shaft 908 to which external gear wheel 910 is mounted. Therefore, when blocking member disk 912 is prevented from rotating, so is external gear wheel 910 which, by its coaction with other elements previously described, is operable to put the lock in condition for unlocking.
Non-magnetic locking member disk 912 is preferably provided with a slight recess 914 , as best seen in FIG. 9, with a through aperture 916 passing through the recessed portion to selectively receive a pin therethrough.
Also mounted within casing 902 is a small magnetic coil, e.g., a voice coil 918 mounted concentrically with an extending portion of axle 908 supported at a rear wall of casing 902 in a bearing 920 . The voice coil is free to move axially of axle 908 and is biased toward rotor 906 and blocking member disk 912 by one or more springs 922 acting against the back end of and within casing 902 . At the end of voice coil 918 closest to blocking member disk 912 , there is mounted a cantilevered pin 924 which normally extends through aperture 916 in blocking member disk 912 , as shown in FIG. 9 . This is the normal situation when the lock is in its locked state. Voice coil 918 is not rotatable about or with axle 908 but can merely slide axially thereof.
A permanent magnet 926 is mounted inside casing 902 with its north and south poles aligned in such a manner that when an electric current is provided to voice coil 918 , an electromagnetic field generated therein produces a pole of like kind so that mounted permanent magnet 926 repells voice coil 918 axially of axle 908 . Consequently, when a sufficient electric current is provided to voice coil 918 , and the magnetic field thereof interacts with permanent magnet 926 to overcome the biasing force of springs 922 , voice coil 918 bodily moves away from blocking member disk 912 . In doing so, it causes pin 924 to be totally extracted from aperture 916 in blocking member disk 912 . So long as such a current continues to be provided to voice coil 918 , and pin 924 remains retracted entirely out of aperture 916 in blocking member disk 912 , blocking member disk 912 , rotor 906 , shaft 908 and external gear wheel 910 are then free to rotate. On the other hand, so long as such an electrical current is not being provided to voice coil 918 , springs 922 force it in such a direction that when the distal end of pin 924 becomes aligned with aperture 916 in blocking member disk 912 it projects therethrough and prevents rotation of axle 908 and external gear wheel 910 mounted thereto.
In known manner, voice coil 918 is connected in conjunction with windings 904 of the electric motor (not numbered), which is used in the same manner as electric motor 300 of the previous embodiments. The electric current which activates voice coil 918 into retracting pin 924 out of blocking member disk 912 does so just before passing of electric current through windings 904 causes rotor 906 to turn axle 908 and, thus, external gear wheel 910 .
As will be appreciated, to avoid binding between pin 924 and the edges defining aperture 916 in blocking member disk 912 , the pin must be retracted before windings 904 generate enough torque on rotor 906 and blocking member disk 912 to turn them inside casing 902 . As a practical matter, there are numerous known mechanisms and techniques for delaying the flow of electrical current to coils 904 until pin 924 has been entirely retracted from aperture 916 , thereby setting rotor 906 free to turn.
In practice, the security device illustrated in FIG. 9 acts to prevent rotation of external gear wheel 910 under the action of an external spurious or intentionally applied magnetic field, which, otherwise, might actually cause rotation of rotor 906 . Thus, if an unauthorized person positions equipment capable of generating a strong rotating field immediately adjacent the locking device of this invention, and rotor 906 rotates by coacting with the imposed rotating field, the lock might be engaged and unlocked without the input of an authorized combination code. The security device illustrated in FIG. 9 would prevent such unauthorized opening of the lock. Since the externally imposed unauthorized rotating electromagnetic field would have no influence on the non-rotatable voice coil 918 and its pin 924 extended through aperture 916 , such a very small light pin 924 very efficiently prevents unauthorized rotation of axis 908 and external gear wheel 910 .
It may be theoretically possible to apply a strong inertial force, e.g., by a violent blow, to the lock along the direction of the axis of axle 908 , sufficient to cause voice coil 918 to compress springs 922 . While doing so, in theory one could retract pin 924 from aperture 916 while, simultaneously, applying a strong rotating external magnetic field to rotate rotor 906 . However, since most safes are very heavy or are built into a structure, the likelihood of such a complex contrivance putting the lock into condition for unlocking for practical purposes is eliminated by the presence of the security device per FIG. 9 .
Persons of ordinary skill in the art will appreciate that the performance of the voice coil and pin 924 attached thereto, involving retraction during the provision of a small electric current to the voice coil, can be utilized under other comparable circumstances to prevent movement of an element capable of coacting with pin 924 , e.g., a sliding element that may be employed as a magnetic key, or the like.
Voice coil 918 is preferably connected in series with winding coils 904 of the electric motor in such a manner that when an electrical current is provided under the control of the microprocessor to enable rotor 906 to turn, the same current causes voice coil 918 to act against springs 922 to withdraw pin 924 from aperture 916 of disk 912 . Only then can disk 912 and the rotor 906 turn to rotate the toothed element 910 into an engageable position to allow the user to apply manual force to lock bolt 212 to move it to its unlocking position. Rotation of rotor 906 by the imposition of an external magnetic field is prevented by this simple structure, while normal authorized opening of the lock mechanism is automatically made possible.
In this manner, by the use of relatively inexpensive and commonly available elements, e.g., a voice coil, springs and essential wiring, additional security can be provided against unauthorized unlocking of the locking mechanism as described hereinabove.
An alternative security device is illustrated in FIGS. 10 and 10A. In such a device, shown sharing a common ferrous casing 1002 , electric motor 300 utilizes a small rotor 1004 mounted coaxially to the motor axle 1006 , rotor 1004 having a knurled or otherwise roughened outer peripheral surface 1008 . Surrounding rotor 1004 , but at a small distance radially outward therefrom, is an annular ring 1010 of a non-ferrous material tightly fitted within ferrous casing 1002 .
As best seen in FIG. 10A, at four equally separated radial locations in non-ferrous annular ring 1010 , there are provided four radial holes 1012 having axes in a common plane. Inside each radial hole 1012 , there is provided a small hardened linear magnet 1014 which is shaped and sized to be freely slidable within radial hole 1012 . Each of the hardened magnets 1014 has a sharp point at its end nearest to the knurled surface 1008 of rotor 1004 . These magnets 1014 are disposed in pairs, with the two magnets of each pair having “like magnetic poles” opposite to each other in a substantially radial direction with respect to the axis of axle 1006 of electric motor 300 . By this arrangement, the two magnets in each pair of magnets tend to repel each other so that they remain loosely held within their corresponding radial holes 1012 but with their respective sharp points magnetically maintained away from the knurled surface 1008 of rotor 1004 .
Under the above-described circumstances, with the magnets, by pairs, staying away from the knurled surface 1008 , the rotor of electric motor 300 remains free to operate as described previously, i.e., to turn between its two detent positions upon the reception of the required small electrical power pulse under the control of the microprocessor. However, should an unauthorized attempt be made to unlock the locking mechanism by the imposition of a large magnetic field upon the locking mechanism, the pairs of magnets will no longer balance each other radially outwardly and, therefore, their sharp ends will come into contact with knurled surface 1008 of rotor 1004 and will prevent rotation thereof. Consequently, the rotor of electric motor 300 also cannot turn and the mechanism cannot be put into condition for operation in any of its embodiments as described hereinabove. This mechanism thus insures safety against attempts at unauthorized opening of the locking mechanism by the imposition of extraneously provided large magnetic or electrical fields.
It should be appreciated that persons of ordinary skill in the art, armed with the above disclosure, will consider variations and modifications of the disclosed embodiments and various aspects of this invention. Consequently, the disclosed embodiments are intended to be merely illustrative in nature and not as limiting. The scope of this invention, therefore, is limited solely by the claims appended below. | A self-powered electric lock includes a lock bolt and a first engagement element having disengaged and engageable positions. An electric actuator includes an output operative to move the first engagement element to its engageable position. A manually operated rotatable member is operatively coupled to the first engagement element when the first engagement element is in its engageable position. A lock bolt drive mechanism is coupled to the lock bolt and to the first engagement element when the first engagement element is in its engageable position. The movable output moves the first engagement element to its engageable position upon input of correct electronic data. An electricity generator is coupled to the manually operated rotatable member. The electricity powers the electric actuator and an electronic data input device. The manually operated rotatable member is also used to actuate the lock bolt drive mechanism and retract the lock bolt. | 61,659 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims benefit as a Divisional Continuation of application. Ser. No. 12/091,749, filed Aug. 1, 2008, which claims benefit of PCT Appln. No. PCT/GB2006/003983, filed Oct. 27, 2006, and United Kingdom Appln. No. GB0521991.0, filed on Oct. 28, 2005, the entire contents of which are hereby incorporated by reference as if fully set forth herein, under 35 U.S.C. §120.
FIELD OF THE INVENTION
The present invention relates to agents which bind the cell surface marker Siglec-9 and their use in the treatment of cell proliferation disorders and assays.
BACKGROUND
Sialic acid-binding immunoglobulin-like lectins (Siglec(s)) are I-type lectins that are expressed by a number of cells including cells of the haematopoietic system. The Siglecs comprise a number of families of molecules, each characterised by the presence of a N-terminal V-set Ig-like domain, which mediates sialic acid binding, followed by varying numbers of C2-set Ig-like domains 4 .
CD33 and the CD33 related siglecs encompass eight of the 11 human siglecs. These molecules share a high degree of sequence similarity and show significant differences in composition amongst mammalian species. The genes encoding these receptors are clustered on chromosome 19q13.3-13.4 and appear to be predominantly expressed in the haematopoietic and immune systems and exhibit differential expression patterns on most mature cells of the innate immune system including monocytes, macrophages, natural killer cells, neutrophils, eosinophils, basophils, mast cells and dendritic cells 6-14 . All human CD33-related siglecs possess a conserved membrane proximal immunoreceptor tyrosine-based inhibition motif (ITIM), as well as a membrane distal ITIM-like motif in their cytoplasmic tails 5 .
Acute myeloid leukaemia (AML) describes a group of related haematological malignancies resulting from the abnormal proliferation and differentiation of haematopoietic stem cells (HSC) or progenitor cells 1 . In AML, cells fail to differentiate to normal mature blood cells and instead, proliferate uncontrollably. The resulting immature myeloid cells or blast cells, accumulate and rapidly replace bone marrow leading to a decrease in production of red blood cells, white blood cells and platelets. The loss of red blood cells may lead to complications such as anaemia, infection and bleeding. In some cases the blast cells occasionally invade the lymphatic system, spleen or other vital organs.
AML is classified using a combination of morphological and genetic features, with classification evolving from the French-American-British (FAB) 2 to the World Health Organisation 3 systems. This classification system describes the differentiation status of the predominant leukaemic (blast) cells. The degree of differentiation increases with the subtypes M0, M1, M2 and M3, while subtypes M4 and M5 are mostly monocytic in lineage and types M6 and M7 have features of erythrocytes and megakaryocytes respectively 27 .
Leukaemia may be described as abnormal haematopoietic tissue that is initiated by a leukaemic stem cell (LSC) that undergoes an aberrant and poorly regulated process of organogenesis, analogous to that of the normal haematopoietic stem cells (HSC). At present normal haematopoietic stem cells are regarded as CD34 + , CD33 − , CD38 − , CD71 − , CD117 +/− , CD123 − , Lin − while the LSC are regarded as CD34 + , CD33 +/− , CD38 − , CD71 − , CD117 +/− , CD123 + , Lin − . Mutations in the HSC or early progenitors lead to the development of the LSC, which has self renewal capacity. The LSC gives rise to progenitor cells which proliferate and differentiate to leukaemic blast cells.
The exclusive presence of CD33 on AML cells provides a useful marker for the detection of AML cells and a target for antibody based therapies. Mylotarg® is a humanized anti CD33 monoclonal antibody coupled to the potent antibiotic Calicheamicin-γ 1 which has been approved for the treatment of relapsed AML following chemotherapy.
The present invention is based upon the observation by the inventors that the CD-33 related Siglec, Siglec-9 is absent from normal bone marrow myeloid progentitor but expressed in AML and as such provides a potential new target for therapies against cell proliferation and/or differentiation disorders. In particular it is noted that Siglec-9 is expressed on subsets of AML cells associated with severe disease (M4 and M5 FAB classification). Furthermore it has been found that unlike CD33 and Siglec-5, the levels of Siglec-9 in the bone marrow plasma were low or undetectable.
It is among the objects of the present invention to provide additional means of treating cell proliferation and or differentiation disorders, for example, acute myeloid leukaemia, and which mitigate or obviate the problems associated with the prior art.
SUMMARY OF THE INVENTION
In a first aspect, the present invention provides a use of sialic acid-binding immunoglobulin-like lectin-9 (Siglec-9) binding agents for the manufacture of a medicament for the treatment of cell proliferation and/or differentiation disorders.
It is to be understood that the term “cell” may refer to any cell or cell type which expresses Siglec-9 or is Siglec-9 + . In particular, the term “cell” may refer to cells of the immune system, for example the peripheral blood leukocytes such as, for example, CD8 + T cells, B cells, natural killer (NK) cells (CD16 ++ /CD56 − & CD16 + /CD56 + ), monocytes, macrophages and neutrophils. In addition, the term “cell” also encompasses cells of the bone marrow, for example, the haematopoietic stem cells.
In addition, the term “proliferation and/or differentiation disorders” encompasses disorders such as cancer. In particular, “proliferation and/or differentiation disorders” may relate to haematological malignancies including, for example, malignant disorders of the monocytic, macrophage and histiocytic lineage and may also include acute myeloid lukeaemia (AML). Table 1 details a number of diseases which are to be considered encompassed by the terms “proliferation and/or differentiation” disorders in accordance with the present invention.
TABLE 1
Cell proliferation disorders and the corresponding WHO
classification assignment code.
Disease
WHO classification
AML with inv(16)(p13q22)
WHO 9871/3
Acute myelomonocytic leukaemia
WHO 9867/3
Acute monoblastic and monocytic
WHO 9891/3
leukaemia
Chronic myelomonocytic leukaemia
WHO 9945/3
Juvenile myelomonocytic leukaemia
WHO 9946/3
Histiocytic sarcoma
WHO 9755/3
Langerhans cell histiocytosis
WHO 9751/1
Langerhans cell sarcoma
WHO 9756/3
Binding agents of the present invention may bind to or otherwise associate with Siglec-9, and may include, for example, small organic molecules, peptides, carbohydrates or antibodies.
Advantageously the binding agent may be an antibody, for example a polyclonal antibody or a monoclonal antibody which specifically binds to Siglec-9. Advantageously, the antibody does not induce complement mediated or antibody dependant cellular cytotoxicity (ADCC). The techniques used to generate monoclonal antibodies are well known in the art and an exemplary monoclonal antibody is described by Zhang et al, 1996 (S. Biol. Chem. 225: 22121-22126). Furthermore, a person of skill in the art would be able to further modify antibodies (or other binding agents) of the present invention by, for example, modification of the nucleic acid encoding such molecules to, for example, and in the case of an antibody remove the heavy and light chains and “humanise” the molecule.
It should be understood that the term “binding agents” is intended to include fragments thereof which retain the ability to bind or otherwise associate with Siglec-9. Advantageously therefore, the term “antibody” may include whole antibody molecules or fragments thereof which specifically bind to or otherwise associate with Siglec-9. Antibodies may readily be fragmented, for example F(ab) 2 fragments can be generated by treating an antibody with pepsin. The F(ab) 2 fragments may be treated to reduce disulfide bridges to produce Fab fragments. Other techniques allow antibodies to be further fragmented such that they may comprise solely the complimentary determining region(s) (CDR) of the molecule. Such antibody fragments may be known in the art as “domain antibodies” or “nanobodies”.
Antibodies of the present invention may be derived from any species especially mammals, for example a horse, a human or a rodent, for example a rabbit, rat or mouse. Advantageously the antibodies may be modified so as to be “humanised”. The techniques used to humanise antibodies derived from species other than a human are well known in the art. In addition, the nucleic acid encoding a specific antibody may be isolated and further manipulated so as to, for example, improve the binding specificity, “humanise” or adjust the size and/or structure of the molecule. It may be possible, to isolate the nucleic acid encoding the Siglec-9 binding agent, for example an anti-Siglec-9 antibody, by removing specific regions of the nucleic acid encoding the binding agent, to reduce the molecule to comprising specific domains such as, for example, the variable region of an antibody. In addition, it may be possible to alter certain residues comprising the molecule to modulate the structure and/or binding specificity.
Alternatively, the Siglec-9 binding agent may comprise the natural ligand for Siglec-9, or, a fragment, analogue or portion thereof. For example the Siglec-9 binding agent may comprise a carbohydrate which further comprises sialic acid. In addition however other peptide or carbohydrate ligands may easily be identified by screening, for example, peptide phage display libraries, glycopeptide libraries or FV phage display libraries.
The Siglec-9 binding agent may modulate the activity of Siglec-9 and/or may modulate the proliferative and/or differentiative state of a cell, including abnormally or aberrantly proliferating and/or differentiating cells. It should be understood that an “abnormally or aberrantly proliferating and/or differentiating cell” is a cell that, when compared to a normally proliferating or appropriately differentiating cell, exhibits up or down regulated levels of proliferation and/or inappropriate differentiation.
The level of proliferation exhibited by a cell may be tested by means well known in the art. For example, the level of incorporation of radioactive nucleotide analogues such as [3H] thymidine, into newly synthesised nucleic acid, may be used as an indication of a cell's proliferative state. Alternatively, non-radioactive nucleotide analogues, such as, for example Bromodeoxyuridine (BrdU), may also be used to indicate the proliferative status of a cell. The amount of radioactive analogue incorporated into newly synthesised DNA may be determined by means of scintillation counting or autoradiography. Alternatively, and where non-radioactive nucleotide analogues are used (e.g. BrdU), the level of analogue incorporation into newly synthesised nucleic acid may be determined by the use of antibodies, or other molecules, which specifically bind to the nucleotide analogue. It may also be possible to determine the proliferative state of a cell by examining the ability of a cell to maintain and propagate itself in culture, or to detect the presence of certain antigens or markers which are indicative of a proliferating cell. Similarly the differentiative state of a cell may be determined by the presence of specific cell markers or by morphological analysis. In addition, it may be possible to monitor the proliferation of a particular population of cells by the addition of a fluorescent dye such as, for example, carboxyfluorecein diacetate succinimidyl ester (CDSE) and the use of flow cytometry. In such cases, as the cells proliferate the level of dye per cell decreases with each division.
Preferably, the Siglec-9 binding agent, once bound, is internalised such that the binding agent is delivered to the interior of the cell or to a compartment or vesicle within the cell. In one embodiment of the present invention the Siglec-9 binding agent may initiate and/or affect its internalisation. Alternatively however, the binding agent may bind or otherwise associate with Siglec-9 but may not be internalised. As such the Siglec-9 binding agent may modulate the proliferative and/or differentiative state of a cell while bound at the cell surface or upon internalisation.
Advantageously the Siglec-9 binding agent may comprise a binding portion, capable of interacting/binding or otherwise associating with Siglec-9, and an active portion capable of modulating the proliferative and/or differentiative state of a cell. The active portion of the binding agent may, for example, be fused, linked, bound, conjugated, joined or otherwise associated with the binding portion and hereinafter, the active portion of the binding agent is to be regarded as “linked” to the binding portion.
Additionally, or alternatively, the active portion of the binding agent may comprise a heterologous molecule, for example a small organic molecule, peptide, carbodhydrate or nucleic acid, linked to the binding portion of the Siglec-9 binding agent.
The techniques used to fuse, link, bind, conjugate, join or associate one molecule to another are well known in the art and are described by Harlow & Lane in “Antibodies: A Laboratory Manual” and by B. Lo in “Antibody Engineering: Methods and Protocols”. A molecule, for example a peptide, may be fused, linked, bound, conjugated, joined or otherwise associated with an antibody by means of the recombinant techniques discussed in detail in “Molecular Cloning: A Laboratory Manual” by Sambrook and Russell. Alternatively, covalent interactions between molecules may be established under certain conditions and after suitable preparation of the molecules to be linked.
Advantageously, the binding portion and the active portion of the Siglec-9 binding agent may be linked together such that upon exposure to certain conditions or agents, the linked molecules are separated. In the present case, the binding portion and active portion of the Siglec-9 binding agent may be linked together by a linking region which may comprise a portion which is sensitive to enzymatic cleavage or changes in environmental conditions such as salt concentration, pH and/or temperature. Such linking regions are well known in the art and may include, for example, moieties capable of affecting the hydrolytic release of, for example, the active portion from the binding portion of the Siglec-9 binding agent in response to, for example, a change in pH.
Thus, where the Siglec-9 binding agent is capable of modulating the proliferative and/or differentiative state of a cell, the term “active portion” may be taken to refer to the Siglec-9 binding agent as a whole. Alternatively however, the term “active portion” may be taken to refer to a portion of the binding agent. Moreover “active portion” may also refer to a molecule, heterologous or otherwise, which, through any means described herein and known in the art, is linked to the Siglec-9 binding agent.
Advantageously, and once bound to Siglec-9, the active portion of the Siglec-9 hinging agent may be internalised such that its activity is directed to the interior of the cell, Alternatively, the active portion of the Siglec-9 binding agent may remain at or near the cell surface from where it may modulate the proliferative and/or differentiative state of a cell.
The active portion may, for example, render an abnormally or aberrantly proliferating and/or differentiating cell, quiescent or dead. In one embodiment of the present invention the active portion may, for example, modulate some aspect of cell metabolism or cause a cell to die. Cell death may occur as a result of exposure to a toxic substance, for example a heavy metal, toxin or toxoid, or via the activation of programmed cell death pathways (apoptosis). In addition, cell death may occur, for example, via the induction of cell lysis, the modulation of one or more aspects of cell metabolism and/or modulation of cell systems such as cell membrane pumps/transporters or protein synthesis components.
The active portion of the Siglec-9 binding agent may comprise a cytotoxic moiety which may result in cell death or may render certain pathways, proteins, molecules or nucleic acids inactive, inhibited or otherwise modulated such that the cell is unable to function correctly. Additionally, the Siglec-9 binding agent may increase or decrease the rate of certain metabolic pathways, or may modulate the production of certain proteins, nucleic acids or other molecules such that the cell is unable to function correctly.
Siglec-9 binding agents of the present invention may also may also include agents which specifically modulate protein and/or nucleic acid synthesis. For example the binding agent may modulate or interact with specific enzymes or ribosomes.
It is particularly advantageous to use Siglec-9 as a target molecule for binding agents of the present invention, as the levels of cell-free Siglec-9 are considerably lower than for other related Siglecs. It should be noted that “cell-free Siglec” refers to Siglec molecules which are not associated with a cell and which are detectable in the plasma fraction of whole blood. Accordingly “cell-free” Siglec-9 may also be referred to as or “soluble” or “plasma” Siglec-9. By way of example, the level of Siglec-5 and CD-33 detectable in plasma is significantly higher than the level of Siglec-9 and as such, binding agents with specificity for Siglec-9 are less likely to be neutralised or absorbed by soluble ligand. Thus, Siglec-9 binding agents may be more efficacious than binding agents specific for other siglec molecules.
It has been observed that Siglec-9 is expressed on subsets of AML cells associated with severe disease. As such, the use of Siglec-9 as a target molecule for agents of the present invention may facilitate the identification and/or diagnosis of patients with severe disease (M4 and M5 FAB classification) and/or may provide an effective drug target for severe disease.
In one embodiment of the present invention, the active portion of the Siglec-9 binding agent may comprise the cytotoxic agent calicheamicin-γ1.
Thus in a second aspect of the present invention there is provided a use of a siglec-9 binding agent for the treatment of cell proliferation and differentiation disorders, wherein the Siglec-9 binding agent comprises an antibody which specifically binds to Siglec-9 conjugated to calicheamicin-γ1.
Advantageously, the Siglec-9 binding agents described herein may be formulated as sterile pharmaceutical compositions comprising a pharmaceutically acceptable carrier, diluent or excipient. Such carriers, diluents or excipients are well known to one of skill in the art and may include, for example, water, saline, phosphate buffered saline, dextrose, glycerol, ethanol, ion exchangers, alumina, aluminium stearate, lecithin, serum proteins, such as serum albumin, buffer substances such as phosphates, glycine, sorbic acid, potassium sorbate, partial glyceride mixtures of saturated vegetable fatty acids, lactic acid, water salts or electrolytes, such as protamine sulphate, disodium hydrogen phosphate, potassium hydrogen phosphate, sodium chloride, zinc salts, colloidal silica, magnesium trisilicate, polyvinyl pyrrolidone, cyclodextrins, such as αcyclodextrin, βcyclodextrin, sulfobutylether 7 -βcyclodextrin and hydroxypropyl-β-cyclodextrin, cellulose-based substances, polyethylene glycon, sodium carboxymethylcellulose, polyacrylates, waxes, polyethylene-polypropylene-block polymers, polyethylene glycol and wool fat and the like, or combinations thereof.
Furthermore, the Siglec-9 binding agents may be administered in combination with another treatment. For example, Siglec-9 binding agents may be administered in combination with agents capable of binding other Siglecs, for example Siglec-3 or 5. Additionally or alternatively, the Siglec-9 binding agent may be administered in combination with antibiotic, antifungal or antiviral agents or in combination with a chemotherapeutic agent, an immunostimulatory compound or drug, an oligonucleotide, a cytokine, hot/none or the like.
In a second aspect of the present invention there is provided a method of treating a subject having a cell proliferation and/or differentiation disorder comprising administering to said subject an effective amount of an agent capable of binding Siglec-9.
The medicaments described herein may be formulated to comprise one or more binding agents. For example, the medicament may comprise one or more Siglec-9 binding agents or a Siglec-9 binding agent and an agent capable of binding another component of a Siglec-9 + cell. For example, the medicament may further comprise agents which are capable of binding CD33 or a CD33 related Siglec.
In a third aspect of the present invention, there is provided a method of screening for agents capable of binding Siglec-9 said method comprising the steps of
a) contacting a test agent with a cell expressing Siglec-9; and b) detecting an interaction between the test agent and Siglec-9.
Interactions between molecules may be detected by techniques such as polyacrylamide gel-electrophoresis (PAGE), enzyme linked immunosorbant assay (ELISA), Western blot or immunoblot. By way of example, cells expressing Siglec-9 or the Siglec-9 molecule may be adhered or coated on to, for example, the surface of a microtitre plate. A test agent may then be applied to the cells or Siglec-9, under conditions permitting the interaction of Siglec-9 with the test agent. After a suitable wash step an antibody either specifically reactive to Siglec-9 or to the test agent may be added under conditions suitable to permit the interaction of said antibody with its epitope. Antibody-antigen interactions may then be detected by any suitable means. For example the antibody may be conjugated to a compound capable of reporting a level of bound antibody by a colorimetric, chemiluminescent or bioluminescent reaction. such compounds may include, but are not limited to, horse radish peroxidase (HRP) and alkaline phosphatase (AlkP). Additionally or alternatively, binding between a test agent and Siglec-9 may be determined by means electrophoresis techniques such as, for example, a “band shift” assay. By way of example, a test agent may first be incubated or contacted with Siglec-9, under conditions permitting the interaction of Siglec-9 with the test agent. Such an incubation period may result in the formation of a Siglec-9/test agent complex and such complexes may easily be detected by subjecting a sample to electrophoresis. Specifically, the presence of a Siglec-9/test agent complex may be detected by comparing the migration of the sample with the migration of a control sample under electrophoresis. It is to be expected that a Siglec-9/test agent complex would migrate less than either Siglec-9 or the test agent when subjected to electrophoresis independently. Altered migration under electrophoresis may manifest as a “band shift”. By “control sample”, it is meant a sample of Siglec-9 or test agent which has not been contacted to either Siglec-9 or test agent prior to electrophoresis.
The above described method may be altered so as to provide a method of screening for agents which bind to Siglec-9 and which are also capable of modulating the proliferative and/or differentiative state of a cell. Such a method may comprise the steps of
a) contacting a test agent with a cell expressing Siglec-9; and b) comparing the proliferation and/or differentiation of the cell of step (a) with a control cell.
It is to be understood that the cell used in step (a) may be an abnormally or aberrantly proliferating cell. Alternatively, the cell may be a normally proliferating or normally or appropriately differentiated cell.
It is to be understood that “control cell” relates to a cell which corresponds to that used in the test agent screening assay (step a), but which has not been exposed or contacted to the test agent.
Alternatively the method may comprise the additional step of fusing, linking, binding, conjugating, joining or associating a test agent to/with a known Siglec-9 binding agent to form a “hybrid” Siglec-9 molecule and contacting a cell with the “hybrid” Siglec-9 binding agent. In this way it may be possible to determine whether or not an agent is capable of modulating the proliferative and/or differentiative state of cell by comparing the proliferation and/or differentiation of the cell with a control cell as described above. In this particular method, in addition to the use of a control cell which has not been exposed to the test agent, it may be desirable to use a control cell which has not been exposed to the known Siglec-9 binding agent. In this way it would be possible to determine whether any observed effect upon cell proliferation or differentiation was due to the test agent.
It may be possible to determine the proliferative state of a cell by using the techniques described in detail above. Briefly, these may include the use of radioactive and non-radioactive nucleotide analogues and/or the detection of certain antigens or markers which are indicative of a particular state of proliferation. Similarly, the differentiative state of a cell may be determined by the presence of specific cell markers or by morphological analysis.
In a fourth aspect of the present invention, there is provided a method of detecting a cell proliferation and/or differentiation disorder in a sample obtained from a subject suspected of having a cell proliferation and/or differentiation disorder, said method comprising the steps of subject comprising the steps of;
a) obtaining a sample from a patient;
b) contacting the sample with an agent capable of binding Siglec-9; and
c) detecting an interaction between the binding agent and Siglec-9,
wherein the presence of Siglec-9 is indicative of a cell proliferation and or differentiation disorder.
The method may further comprise the step of comparing the level of Siglec-9 detected in the sample derived from the subject, with the level of siglec-9 present in a control sample. By “control sample” it is meant a sample, preferably obtained from a substantially identical tissue or body fluid, but which is derived from a subject or source not having a cell proliferation and or differentiation disorder.
A suitable sample may include a sample or biopsy of a particular tissue or body fluid. For example a cell proliferation and/or differentiation disorder may be detected in samples of tissue comprising cells and obtained from, for example, the bone marrow or lymph nodes, or from body fluid samples such as blood or saliva.
In a fifth aspect of the present invention, there is provided a method of obtaining abnormally or aberrantly proliferating and/or differentiating cells, said method comprising the steps of;
a) immobilising a siglec-9 binding agent on to a support substrate; and
b) contacting said immobilised Siglec-9 binding agent with a cell sample.
The solid support may, for example, be agarose, sepharose, polyacrylamide, agarose/polyacrylamide co-polymers, dextran, cellulose, polypropylene, polycarbonate, nitocellulose, glass paper or any other suitable substance capable of providing a suitable solid support.
Advantageously, the solid support may be in the form of granules, a powder or a gel suitable for use in chromatography such as those available from Amersham Biosciences.
The Siglec-9 binding agent may further comprise a binding moiety providing a means of coupling said Siglec-9 binding agent to the solid support. Such a binding moiety could be for example a peptide or other small chemical moiety, for example biotin/streptavidin.
In a further embodiment of the present invention, the binding moiety may comprise any of the oligopeptides His n where n is 4-20, preferably n is 5-10 and more preferably n is 6. Such oligopeptides have a high affinity for divalent nickel (Ni), enabling the Siglec-9 binding agent to be coupled to the nickel chelating resin Ni 2+ -NTA-agarose.
Alternatively, and in a further embodiment of the present invention, the Siglec-9 binding agent may be chemically cross-linked to the solid support. Advantageously the Siglec-9 binding agent may be chemically cross-linked to the solid support by means of, for example, activation of the solid support by the addition of cyanogen bromide (CNBr) as disclosed by Axen et al (1967). Briefly, upon addition of CNBr the solid support reacts rapidly at pH 8-9 with free amino acid groups in the polypeptide to be cross-linked to the solid support. Preferably the solid support for use in this way is agarose, for example CNBr-activated agarose.
Advantageously, the Siglec-9 binding agent may be coupled to the solid support by means of an antibody or fragment thereof which specifically reacts with a portion of said binding agent. Preferably the antibody is coupled to the suitable solid support. Advantageously, the antibody or fragments thereof useful in this way may be monoclonal antibodies or fragments which have an affinity for the Silec-9 binding agent. The techniques of monoclonal antibody production are well known to one of ordinary skill in the art.
Alternatively, the method described above may be used to remove cells expressing siglec-9 from a sample or solution comprising a cell population. In this way it may be possible to remove from a population of cells, those cells which aberrantly proliferate and/or which inappropriately differentiate, so as to obtain a population of cells which consists substantially of cells which normally proliferate and/or differentiate. Cells, for use in this particular method may be derived from blood and/or bone marrow. Accordingly, a sample comprising cells obtained from (or provided by) a patient, or subject with a cell proliferation and/or differentiation disorder such as acute myeloid leukaemia, may be depleted of substantially all of the cells which aberrantly proliferate or inappropriately differentiate. Upon removal of these cells from the cell sample, the remaining cells may be returned to the patient and/or subject.
The method for removing siglec-9 expressing cells from a population of cells may be combined with a process which removes cells which express CD33. For example, a siglec-9 binding agent and a CD33 binding agent may be immobilised on a suitable substrate. By contacting the immobilised siglec-9/CD33 binding agents with a sample comprising a population of cells, those cells expressing CD33 and/or siglec-9 will be removed from the cell population. Additionally, such methods may be combined with chemotherapy to provide a comprehensive treatment strategy to those suffering from a cell proliferation and/or differentiation disorder.
DETAILED DESCRIPTION
The present invention will now be described further by way of example and with reference to the Figures which show:
FIG. 1 . Expression of CD33-related Siglecs on AML cells. Mononuclear AML bone marrow cells from sample XXI (see Table 2) were stained with anti-CD33-biotin mAb and the indicated FITC-labelled anti-Siglec mAbs, followed by streptavidin-APC and analysed by flow cytometry. The non-viable cells labelled with 7-AAD were not included in the analyses. The left quadrants were set to include more than 99% of cells labelled by the isotype control. The percentages of CD33 + /Siglec + cells are shown.
FIG. 2 . Co-expression of Siglec-7 and Siglec-5 on the Siglec-9-positive subset of AML cells. Mononuclear AML bone marrow cells from samples I (top panels) and XXI (lower panels) (see Table 2) were stained with anti-Siglec-9-FITC mAb and either anti-Siglec-5-biotin or anti-Siglec-7-biotin mAbs, followed by streptavidin-APC and analysed by flow cytometry.
FIG. 3 . Phenotypic characterisation of Siglec-9-positive AML cells by flow cytometry. A. Mononuclear AML bone marrow cells from sample II (see Table 2) were stained with anti-Siglec-9-FITC mAb in conjunction with one of the following mAbs: anti-CD38-biotin, anti-CD123-biotin (both followed by streptavidin-APC), anti-CD117-PE or anti-CD14-PE. B. AML cells were stained with anti-CD33-FITC or anti-Siglec-9-FITC mAbs in conjunction with anti-CD34 class II-biotin followed by streptavidin-APC. Examples of 3 AML, samples (Table 2) are shown (top panel, sample I, 29% CD34 + ; middle panel, sample II, 2.5% CD34; bottom panel sample XIX, 31% CD34 + ). The percentages of double-positive cells are shown for each dot-plot.
FIG. 4 . May-Grunwald-Giemsa staining of AML cells and normal bone marrow cells. Mononuclear AML bone marrow cells (A) and mononuclear normal bone marrow cells (B) were immunomagnetically sorted into Siglec-9-positive and -negative fractions and cytospins stained using May-Grunwald-Giemsa. Cells within the Siglec-9-positive fractions are enriched for cells of the monocytic lineage.
FIG. 5 . Expression of CD33-related Siglecs on normal bone marrow cells. Mononuclear bone marrow cells were stained with the indicated FITC-labeled mAbs and analysed by flow cytometry. A. A plot of forward scatter (FSC) versus side scatter (SSC) permits definition of three populations: R2, SSC low ; R3, SSC medium ; R4, SSC high , B. The grey histograms show expression of CD33-related Siglecs using the indicated mAbs on the three subsets of cells defined above. White histograms show staining with the isotype control.
FIG. 6 . Characterisation of Siglec-positive subsets in normal bone marrow. A. Bone marrow cells were labeled with anti-CD33-APC and anti-Siglec-9-FITC together with either anti-Siglec-5-biotin or anti-Siglec-7-biotin followed by streptavidin-PE. Two Siglec-9 positive populations are defined: Gate 1, CD33 high , Siglec-9 + ; Gate 2, CD33 medium , Siglec-9 + . The histograms show expression of Siglec-5 and Siglec-7 on each gated subpopulation. B. Bone marrow cells were labeled with anti-Siglec-9-FITC together with either anti-CD38-biotin or anti-CD123-biotin followed by streptavidin-APC, or anti-CD14-PE. The percentages of single and double positive cells are shown. C. Bone marrow cells were stained with anti-CD34-biotin and either CD33-FITC, anti-Siglec-5-FITC, anti-Siglec-7-FITC or anti-Siglec-9-FITC followed by streptavidin-APC. The CD34 + cells were gated (M1, grey histogram, left panel) and analysed for expression of CD33, and Siglecs-5, -7 and -9 (grey histograms, right panels). White histograms show labeling of CD34 + cells with isotype matched control.
FIG. 7 . Internalisation of anti-Siglec-9 mAb. A. Mononuclear AML bone marrow cells from samples XVI, XIX and XXI (left panel) or RBL cells stably transfected with wild type (WT) or (Y1F) or (Y2F) mutant forms of Siglec-9 (right panel) were labelled with anti-Siglec-9-Alexa-488 mAb for 45 min on ice, washed and then incubated for 40 or 240 min at 37° C. The remaining surface anti-Siglec-9 mAb was detected using goat anti-mouse-APC. The graphs show the anti-Siglec-9 mAb remaining at the surface expressed as a percentage of the starting values B. Internalisation assays were carried out as described in (A) and the levels of total cell associated anti-Siglec-9-Alexa-488 was measured at each time point. The increases seen in the right panel reflect a time-dependent gain in autofluorescence of RBL cells detected on the FL-1 channel. The graphs show the total remaining anti-Siglec-9 mAb expressed as a percentage of the starting values.
FIG. 8 . Confocal microscopy analysis of internalisation of anti-Siglec-9 mAb by transfected RBL cells. WT (A, B) or Y1F (C) or Y2F (D) mutant forms of Siglec-9-transfected RBL cells were incubated on ice with anti-Siglec-9-Alexa-488 mAb for 1 h, washed and incubated for 1 h at 37° C. (B, C, D) or for 1 h on ice (A). Internalization was stopped by chilling on ice and the plasma membrane labeled with cholera toxin B subunit-Alexa-594. After washing, the cells were fixed with 4% paraformaldehyde and examined by confocal microscopy.
MATERIALS AND METHODS
AML Patients and Normal Bone Marrow and Blood Donors
Bone marrow aspirates from AML patients and bone marrow samples from otherwise healthy patients undergoing hip replacement surgery were obtained after informed consent. AML samples were stored in the Tayside Cancer Tissue Bank. The study was approved by the Tayside Cancer Tissue Committee (Ref. 04/S1401/85), which represents the Tayside Committee for Medical Research Ethics for studies involving banked tissue. Mononuclear cells (MNC) were purified by Ficoll-Paque™ Plus (Amersham Biosciences, Bucks, UK) density gradient centrifugation. AML cell aliquots were stored in liquid nitrogen and normal MNC were directly used for the experiments. Cryopreserved samples were thawed and incubated in RPMI 1640 (with L-glutamine) medium supplemented with 20% PCS, 1% penicillin/streptomycin, 10 mM HEPES buffer (all reagents were from Invitrogen Gibco, Paisley, UK) for 90 min at 37° C., 5% CO 2 prior to experiments. Bone marrow plasma was prepared by centrifugation of anticoagulated whole bone marrow aspirates and stored at −80° C. Blood samples for preparation of serum were collected from laboratory volunteers according to local ethical guidelines,
Antibodies
Specific monoclonal antibodies (mAbs) to the following CD33-related siglecs were produced in our laboratory: CD33 (6C5), Siglec-5 (1A5) 6 , Siglec-7 (S75a) 7 , Siglec-8 (7C9) 9 , Siglec-9 (KALLI) 11 , Siglec-10 (5G6) 12 and Siglec-11 (4C4) 13 . All are mouse IgG1 except 4C4 which is IgG2c. IgGs were purified from tissue culture supernatants using protein G Sepharose (Sigma, Dorset, UK) and labelled with fluorescein-5-isothiocyanate (isomer 1) (FITC) (Invitrogen, Paisley, UK). Anti-Siglec-5 and -Siglec-7 IgGs were labelled with EZ-Link biotin (Pierce, Rockford) and anti-CD33, -Siglec-8 and -Siglec-9 IgGs were labelled with Alexa Fluor 488 (Invitrogen). The following commercial Abs were also used: anti-CD33-biotin (WM53, Serotec, Oxford, UK), anti-CD33-APC (WM53, Serotec), anti-Siglec-6 (E20-1232, BD Pharmingen, Oxford, UK), anti-CD34-biotin (QBEND, Serotec), anti-CD14-PE (Caltag-Medsystems, Buckingham, UK), anti-CD38-biotin (HIT2, Caltag-Medsystems), anti-CD123-biotin (6H6, eBioscience, San Diego, USA), anti-CD117 (104D2, Caltag-Medsystems), anti-mouse immunoglobulin-FITC (DAKO, Ely, UK).
Flow Cytometry
3−4×10 5 cells were stained with saturating concentrations of the indicated mAbs for 45 min on ice. After washing, the cells were incubated with streptavidin-APC or -PE for 30 min on ice and after an additional washing step the cells were resuspended in PBS containing 0.25% bovine serum albumin, 10 mM sodium azide and 7-amino actinomycin D (7-AAD). For Siglec-6 staining, cells were incubated with saturating levels of purified Siglec-6 mAb, followed by anti-mouse IgG-FITC. All flow cytometry analysis was performed using either a FACS Calibur or LSR flow cytometer (3D Biosciences) and CeliQuest software. In each case the negative quadrant was set to include more than 99% of the isotype control-labeled cells and the non-viable 7-AAD-positive cells were routinely excluded from all FACS analyses.
May-Grunwald-Giemsa Staining of Siglec-9+ and Siglec-9-Cells
AML cells and normal bone marrow cells were labeled with anti-Siglec-9 IgG-FITC followed by anti-FITC-coupled paramagnetic microbeads and magnetically sorted into positive and negative fractions using an AutoMACS system (Miltenyi Biotech, Bisley UK), according to the manufacturer's instructions. The purity of the separated cell fractions was approximately 90% as assessed by flow cytometry. Cytospins were prepared and stained with May-Grunwald-Giemsa. Images from randomly selected fields were taken with an Axioskop microscope (Zeiss, Jena, Germany), using a 63×L25 oil lens (Zeiss) and Axiovision 3.0 software. Black and white reference was set according to the manufacturer's instructions and the exposure time was 1273 ms.
Colony Forming Assays
AML cells and normal bone marrow cells were labeled with anti-Siglec-9-FITC and sorted into positive and negative fractions using a FACS Vantage SE (BD Biosciences). The purity of the positive fractions was consistently greater than 95%. To control for the potential effect of anti-Siglec-9 mAb on colony forming ability, all experiments included unsorted cells that had been incubated or not with anti-Siglec-9-FITC. FACS sorted cells and control Ab incubated cells were cultured in methylcellulose media (HSC-CFU complete with erythropoietin, Miltenyi Biotech) for 14 days at 37° C., 5% CO 2 , and numbers of CFU-E, BFU-E, CFU-G, CFU-M, CFU-GM and CFU-GEMM scored according to the manufacturer's instructions. The CFU-blast assay was carried as described 19 , using the same culture conditions as for normal bone marrow cells.
Flow Cytometric Analysis of anti-Siglec-9 mAb Internalisation
Cells were labeled with anti-Siglec-9-Alexa-488 mAb for 45 rain on ice. The cells were washed and either stored on ice or incubated for 60 or 240 min at 37° C., 5% CO 2 in complete medium. At each time point, internalization was stopped by placing the tubes on ice. At the end of all incubations, the levels of anti-Siglec-9-Alexa-488 mAb remaining at the cell surface were detected in triplicate using goat anti-mouse-IgG-APC (Caltag-Medsystems) on the FL-4 channel. The total cell-associated Alexa-488-labelled anti-Siglec-9 mAb (surface+internalized) was measured on the FL-1 channel. Anti-Siglec-8-Alexa-488 mAb was used as an isotype control. Internalisation was quantified by subtracting the FL-4 median fluorescence intensity (MFI) obtained with anti-Siglec-8 from the FL-4 MFI obtained with anti-Siglec-9. The FL-4 MFI values of cells kept on ice throughout the experiment were considered as 100%. The total cell-associated anti-Siglec-9 mAb was calculated similarly using the corresponding FL-1 MFI values.
Internalisation Analysed by Confocal Microscopy
Adherent rat basophil leukemia (RBL) cells expressing wild-type or tyrosine to phenylalanine mutant forms of Siglec-9 15 were cultured in 8-well chamber slides (NalgeNunc International, VWR, Leics, UK) and incubated with anti-Siglec-9-Alexa-488 mAb for 1 h on ice. After washing, the cells were incubated in complete medium on ice or for the indicated period of time at 37° C., 5% CO 2 . Internalization was stopped by putting the cells on ice and the plasma membrane labeled with 5 μg/ml cholera toxin B subunit-Alexa-594 (Invitrogen). After washing, the cells were fixed with 4% paraformaldehyde for 10 min at room temperature and mounted in Vectashield Mounting medium DAPI (Vector Laboratories, Peterborough, UK). Slides were examined with a Leica SP2 AOBS confocal microscope equipped with a 63×1.4 oil lens (Leica, Heidelberg, Germany). Excitation/emission settings for different fluorescent labels were as following: Alexa-488, excitation: 488 nm/detected emission: 503-585 nm; Alexa-594, excitation: 594 nm/detected emission: 611-689 nm and DAPI excitation: 405 nm, detected emission: 410-527 nm. All images were processed using Adobe Photoshop CS.
Measurement of Soluble Siglecs
Levels of soluble Siglec-5 and Siglec-9 were measured using enzyme linked immunosorbent assay (ELISA) kits according to the manufacturer's instructions (R&D Systems, Abingdon, UK). An in-house ELISA was developed to measure CD33. Immulon 4 ELISA plates (Dynatech, Chantilly, Va.) were coated overnight at 4° C. with purified 6C5 anti-CD33 mAb at 4 μg/ml in carbonate buffer pH 9.6, followed by either the test sample or a CD33 standard, comprising the CD33 extracellular region fused to enhanced green fluorescent protein, After 1 h at room temperature, wells were washed and incubated with affinity-purified rabbit anti-CD 33, followed by goat anti-rabbit-horse radish peroxidase, ELISAs were developed using O-phenylamine diamine and absorbances measured at 450 μm. All samples were analysed in triplicate at 2 different dilutions in 2 independent assays.
Results
Characterisation of the Expression Pattern of the CD33-Related Siglecs in AML.
To assay expression of the CD33-related siglecs on a collection of 21 cryopreserved AML cell samples, in-house generated anti-siglec mAbs were labelled with FITC and used at a saturating concentration as determined by staining of normal blood leukocytes. For each anti-siglec mAb, two-colour staining was performed using a biotinylated commercial anti-CD33 mAb detected with streptavidin-APC and samples analysed by flow cytometry (Table 2). As expected, 1-step staining with FITC-labelled anti-CD33 mAb gave lower levels of labelling compared with the 2-step staining, reflecting a generally lower sensitivity of directly labelled mAbs (Table 2). A large variation in the percentage of siglec-positive cells was observed, but each siglec was invariably expressed within the CD33+ subset of AML cells ( FIG. 1 ). Using FITC-labelled mAbs and taking a percentage cut-off of 5%, 17 of 21 samples expressed CD33 (median %, 37; median MFI, 25), 12 expressed Siglec-5 (median %, 13.5; median MFI, 27.5), 11 expressed Siglec-9 (median % 25; median MFI, 37), 5 expressed Siglec-7 (median %, 28.5, median MFI, 22.5) and 2 expressed Siglec-10 (median % 10.4; median MFI, 21). No expression of Siglec-8 or Siglec-11 was seen on any sample analysed, and low levels of expression were seen for Siglec-6 in one case (Table 2). Apart from CD33, Siglec-9 was the most strongly expressed of the CD33-related siglecs, both in terms of the percentages of positive cells and the MFI values of the positive subsets. The analysis showed that in seven cases it was expressed on a similar or even higher percentage of AML cells than CD33 (Table 2). A representative sample (XXI, Table 2) in which several CD33-related siglecs were clearly detected on AML cells is shown in FIG. 1 .
Myelomonoblastic (FAB: M4) and monoblastic (FAB: M5) AML cells showed an increased expression of Siglecs-5, -7, -9 and -10 when compared to AML cells with a more immature phenotype (FAB: M0, M1, M2) (Table 2). This result is consistent with earlier studies on expression of Siglec-5 and Siglec-7 on AML cells 17,18 . The expression of Siglecs-5, -7 and -9 on CD33-positive subsets of cells raised the possibility that these molecules were coexpressed on the same subset of AML cells rather than on separate subsets. This was confirmed for two different AML samples using multi-parameter flow cytometry ( FIG. 2 ).
TABLE 2 Expression of the CD33-related siglecs on primary bone marrow AML cells. CD33 CD33 Siglec-5 Siglec-6 Siglec-7 Siglec-8 Siglec-9 Siglec-10 Siglec-11 (2-step)* FITC FITC (2-step)* FITC FITC FITC FITC FITC Sample FAB % % MFI % MFI % % MFI % % MFI % MFI % I M0/M1 98 59 22 5.0 15 ND 2.8 16 (—) 7.0 23 (—) — (—) II M0/M1 84 2.3 27 (—) — ND (—) — (—) 7.9 39 (—) — (—) III M1 99 39 21 (—) — ND (—) — (—) (—) — (—) — (—) IV M1 98 91 25 5.0 15 ND 0.6 16 (—) 1.0 15 (—) — (—) V M1 15 1.1 15 0.6 19 (—) 1.0 17 (—) 1.1 38 (—) — (—) VI M1 85 7.6 16 6.5 30 (—) 0.6 17 (—) 1.7 28 (—) — (—) VII M1 1.1 0.8 44 6.5 50 (—) (—) — (—) 0.6 41 (—) — (—) VIII M1 92 48 31 8.8 28 ND ND — (—) 12 39 (—) — (—) IX M2 55 22 38 35 27 4 † 0.9 21 (—) 4.1 27 (—) — (—) X M2 12 5.7 22 3.5 22 (—) (—) — (—) 2.1 27 (—) — (—) XI M2 79 68 17 1.0 12 (—) 1.2 12 (—) 0.6 17 (—) — (—) XII M2 47 2.4 28 4.0 26 ND 2.1 30 (—) 1.7 32 (—) — (—) XIII M4 70 37 25 14 23 (—) 2.8 20 (—) 43 44 (—) — (—) XIV M4 84 70 44 80 34 ND 45 34 (—) 25 35 1.4 32 (—) XV M4 86 17 16 9.5 17 ND (—) — (—) 1.8 19 1.6 14 (—) XVI M5 92 76 37 22 19 ND 31 22 (—) 53 26 1.5 26 (—) XVII M5 89 23 21 36 31 (—) 26 23 (—) 38 55 13.4 20 (—) XVIII M6 13 6.4 39 6.2 38 ND ND — (—) 7.1 33 ND — ND XIX ND 44 50 26 42 18 ND 33 16 (—) 42 20 4.6 13 (—) XX ND 93 16 32 5.0 29 ND (—) — (—) 17 37 (—) — (—) XXI ND 53 36 50 13 20 ND 23 30 (—) 33 75 7.4 22 (—) FAB, French-American-British classification; MFI, median fluorescence intensity of positive subset; (—), no siglec-positive cells detectable; —, not applicable; ND, not determined. *2-step refers to staining carried out with biotinylated Ab followed by streptavidin-APC (CD33) or unlabelled Ab followed by labelling with anti-mouse- FITC (Siglec-6). † MFI value was 26.
Immunophenotypic Properties and Colony Forming Potential of Siglec-9+ AML Cells
The relatively high expression of Siglec-9 in several cases of AML suggests that this siglec might serve as both a useful marker and a potential therapeutic target in certain subtypes of AML. To further characterise the Siglec-9 + AML subsets, additional phenotypic analyses were carried out, demonstrating that the majority of Siglec-9 + cells were CD38 − , CD123 +/− , CD117 + and CD14 + ( FIG. 3A ). In addition, CD33 + and Siglec-9 + cells were compared for the expression of CD34 (class II) which is known to be expressed on leukemic stem cells (LSC) 20 . The result showed that in 8 of 10 samples analysed, only very few Siglec-9 + cells expressed CD34, unlike CD33, which was detected on a higher percentage of CD34 + cells ( FIG. 3B ). Taken together, the immunophenotype of Siglec-9 + cells was consistent with monocytic cells. This was confirmed by May-Grunwald-Giemsa staining of sorted Siglec-9 + and Siglec-9 − AML cells ( FIG. 4A ).
Although the majority of Siglec-9 + cells lacked expression of CD34 ( FIG. 3B ) the few Siglec-9 + /CD34 + cells could include leukemic cells with blast colony forming potential 19 . To investigate this possibility Siglec-9 + and Siglec-9 − AML cells were purified by FACS sorting and CFU-blast assays in methylcellulose performed for three different AML samples. In all cases, no CFU-blast were detected within the Siglec-9+ fractions, whereas the Siglec-9 − fractions had 2, 200 and 238 CFU-blast colony initiating cells per 105 cells in the three patients' samples analysed. Control experiments with unsorted cells incubated with or without anti-Siglec-9 mAb showed that there was no effect of the mAb on CFU-blast formation (data not shown).
Characterisation of CD33-Related Siglec Expression on Normal Bone Marrow Cells
Apart from CD33 and Siglec-5, there have been no detailed reports on the expression profiles of the CD33-related Siglec family on normal bone marrow cells. This is important in the context of Ab-mediated targeting of AML cells in which it would be desirable to spare normal progenitor cells from cytotoxic effects. Three subpopulations of normal bone marrow cells were defined by flow cytometry according to side scatter (SSC) properties, respectively SSC low ( FIG. 5 , R2), SSC medium ( FIG. 5 , R3) and SSC high ( FIG. 5 , R4) 21 . In four normal bone marrow samples analysed, the expression of the CD33-related Siglecs was mostly confined to the SSC medium and SSC high populations and a representative example is shown in FIG. 5 . The majority of SSC medium cells were strongly positive for CD33 and Siglec-9 and weakly positive for Siglecs-5 and -7. In comparison, the SSC high cells were weakly positive for CD33 and Siglec-5, but mostly negative for Siglec-9 ( FIG. 5 ). Multicolour labeling showed that the SSC medium , CD33 high , Siglec-9 + subpopulation ( FIG. 6A , gate 1) also co-expressed Siglecs-5 and -7. In contrast, the SSC high , CD33 low , Siglec-9 + , ( FIG. 6A , gate 2) cells were only positive for Siglec-5, but negative for Siglec-7. The Siglec-9 + subpopulation was further defined as CD38 − , CD123 +/− , CD14 + and CD34 − ( FIGS. 6B , C). Taken together with May Grunwald Giemsa staining of purified Siglec-9 + cells ( FIG. 4B ), these results indicate that Siglec-9+ cells in normal bone marrow are predominantly immature cells of the monocytic lineage. Examination of CD34 + cells showed that, similar to Siglec-9, Siglec-7 was mostly absent whereas Siglec-5 was detected on ˜5% and CD33 on ˜14% of CD34 + cells ( FIG. 6C ). Myeloid progenitor cells characteristically express CD34 and CD33. Although the majority of Siglec-9 + cells in normal marrow were CD34 − CD33 + , a small fraction (˜1%) of the CD34 + cells were Siglec-9 + ( FIG. 6C ). To investigate whether a subset of progenitors expressed Siglec-9, normal bone marrow cells were sorted into Siglec-9 + and Siglec-9 − cell fractions by flow cytometry and their colony forming ability was measured using a standard methylcellulose-based clonogenic assay. Two independent experiments showed that the Siglec-9 + cell fraction contained no colony forming cells, in contrast to the negative fraction, which contained the expected levels of BFU-E, CFU-E, CFU-G and CFU-GM cells (Table 3).
TABLE 3
Quantification of bone marrow colony forming cells in
Siglec-9-negative and Siglec-9-positive cell fractions after cell sorting.
Cell
CFU-
CFU-
fractions
CFU-E
BFU-E
CFU-G
CFU-M
GM
GEMM
Unsorted
4.5*
5.5
26
11
14.5
0
BM,
[4,5]
[4,7]
[31,21]
[13,9]
[19,9]
[0,0]
No mAb
incubation
Unsorted
2
1.5
38
6
18.5
0
BM,
[2,2]
[0,3]
[41,35]
[6,6]
[18,19]
[0,0]
MAb
incubation
Siglec-
0
1
0
0
0
0
9 + fraction
[0,0]
[2,0]
[0,0]
[0,0]
[0,0]
[0,0]
Siglec-
10.5
15.5
88
19
25
1
9 − fraction
[14,7]
[17,14]
[109,67]
[18,20]
[25,25]
[1,1]
BM, normal bone marrow;
mAb, anti-Siglec-9 mAb.
*The data show the mean of duplicate colonies per well from 1 × 10 4 cells incubated for 14 days in methylcellulose medium supplemented with Stem Cell Factor, GM-CSF, G-CSF, IL-6, IL-3 and erythropoietin.
The brackets show the individual counts for both duplicates. Similar results were obtained in two independent experiments using normal bone marrow from two different donors.
In conclusion, analysis of normal bone marrow showed that Siglecs-5, -7 and -9 are expressed on differentiating cells of the myeloid lineages. In the case of Siglec-9, this receptor is absent from myeloid progenitors in contrast to CD33. Overall, the phenotype of AML cells and primary bone marrow cells that express CD33-related siglecs are similar, suggesting that the CD33-related siglecs are not expressed aberrantly in AML.
Anti-Siglec-9 mAb is Rapidly Internalised by AML Cells and Siglec-9-Transfected Rat Basophil Leukemia Cells
The relatively high expression of Siglec-9 on monocytic AML cells and its absence from myeloid progenitors makes it a potential new candidate for mAb based therapy, aimed at ablating blast cells and lowering the leukemic cell burden in the patient via toxin delivery. For this to be effective, it would be essential that anti-Siglec-9 mAb is internalized upon binding to the cell surface. To analyse mAb internalization, a flow cytometric assay was developed in which cells were labelled with Alexa 488-labelled anti-Siglec-9 mAb on ice and then incubated for varying periods at 37° C. The amount of bound mAb remaining was then measured using APC-labelled anti-mouse Ig followed by flow cytometry. The results of three independent experiments with primary AML samples showed that 30-50% of bound anti-Siglec-9 mAb was internalized within 40 min at 37° C. and up to 90% was internalised by 240 min ( FIG. 7A , left panel). The loss of surface anti-Siglec-9 mAb was due to internalization rather than shedding since the amount of cell-associated Alexa-488-labelled anti-Siglec-9 mAb remained constant during the time-course of the experiment ( FIG. 7B , left panel). To demonstrate directly that Siglec-9 could mediate internalization of anti-Siglec-9 mAb and investigate the role of the two cytoplasmic tyrosine-based signalling motifs (Y1 and Y2), 15 we examined the internalization of anti-Siglec-9 Ab in Siglec-9 stably-transfected RBL cells by flow cytometry and confocal microscopy. Using a similar assay as described above for the AML cells, RBL cells expressing wild-type or Y2F (membrane distal tyrosine changed to phenylalanine) mutant Siglec-9 showed similar rates of endocytosis such that by 40 min, 40-50% of Siglec-9 was internalized ( FIG. 7A , right panel). In comparison, the Siglec-9 Y1F (membrane proximal tyrosine changed to phenylalanine) mutant was internalized more slowly ( FIG. 7A , right panel). The total cell-associated anti-Siglec-9-Alexa-488 appeared to increase slightly due to a gain in autofluoresence over the time-course of the experiment ( FIG. 7B , right panel). Internalization by RBL was confirmed by confocal microscopy in which wild type or Y2F forms of Siglec-9 showed high levels of internalization after 1 h incubation, whereas the Siglec-9 Y1F mutant remained mostly at the cell surface (Data Supplement Figure), These experiments showed that the membrane proximal ITIM of Siglec-9 is required for optimal endocytosis and is consistent with previous studies on CD33 16 .
Soluble Forms of Siglec-9 are Either Low or Undetectable in AML Bone Marrow Plasma Whereas Siglec-5 is Present at High Levels
For an anti-Siglec-9 mAb to function effectively in targeting AML cells in vivo, it is important that high levels of soluble Siglec-9 are absent from plasma, since this might neutralise injected Ab and reduce therapeutic efficacy. Indeed, a high antigenic load of CD33 in blood may significantly affect the clinical outcome following Mylotarg treatment 22 . We therefore investigated the levels of soluble Siglec-9 in bone marrow plasma collected from eight AML patients, including several with M4/M5 FAB status and one patient (AP3, Table 4) shown to have high levels of Siglec-9 + AML cells (sample XIII, Table 2). We also measured soluble CD33 and Siglec-5 for comparison, Undetectable levels of soluble Siglec-9 (limit of detection 1.25 ng/ml) were present in plasma from six patients and very low levels (˜4 ng/ml) were detected in two patients (Table 4), In comparison, low to intermediate levels (4-30 ng/ml) of soluble CD33 were seen in all patients and Siglec-5 was readily detectable in 7 of 8 patients examined, with levels up to ˜500 ng/ml (Table 4). No Siglec-9 could be detected in normal bone marrow plasma or normal blood serum samples, whereas soluble Siglec-5 was seen in all but one. CD33 was detected in one of three normal bone marrow plasma samples and in all normal blood serum samples. In general, levels of Siglec-5 and CD33 were higher in the AML samples than controls and these correlated to some extent with the numbers of circulating blood leukocytes in each patient (Table 4).
TABLE 4 Levels of soluble Siglec-5 and Siglec-9 in bone marrow plasma from AML patients and controls. WBC CD33 Siglec-5 Siglec-9 Sample FAB cells/μl ng/ml* ng/ml ng/ml AP1 M2 2.2 6.4 ± 1.3 (−) (−) AP2 RAEB 2 3.2 ± 0.6 128 ± 12 (−) AP3 M5A 6 4.1 ± 0.9 318 ± 39 (−) AP4 M2 14 0.4 ± 0.4 83 ± 2 (−) AP5 † M4 26 12.2 ± 0.4 451 ± 13 (−) AP6 M5A 107 26.1 ± 0.4 464 ± 44 4.3 ± 0.1 AP7 M5A 407 12.9 ± 0.9 535 ± 95 4.7 ± 0.6 AP8 M2 160 29.6 ± 1.1 359 ± 14 (−) NP1 — ND (−) (−) (−) NP2 — ND (−) 72 ± 5 (−) NP3 — ND 6 ± 0.8 57 ± 0 (−) NS1 — ND 3.2 ± 0.2 104 ± 1 (−) NS2 — ND 0.6 ± 0.2 69 ± 3 (−) NS3 — ND 5.8 ± 0.2 54 ± 32 (−) WBC, white blood cells; AP, AML bone marrow plasma; NP, normal bone marrow plasma; NS, normal blood serum; (−), not detected, — not relevant, ND, not determined. The data show mean ± one standard deviation. FAB, French-American-British classification. † This sample corresponds to sample XIII in Table 2.
Discussion
In this paper we describe the first comprehensive analysis of CD33-related siglec expression in AML. The aim of this screen was to determine if there are additional CD33-related siglecs that could be used for clinical purposes, either as markers to monitor disease or as therapeutic targets. Apart from CD33, Siglec-9 stood out as an interesting new candidate and was shown to be present at similar levels to CD33 in 7 out of 21 AML cases analysed. We also compared the CD33-related siglecs for their expression profile on normal bone marrow cells and demonstrated that, in contrast to CD33, Siglec-9 is absent from myeloid progenitors but was present at similar levels to CD33 on immature cells of the monocytic lineage. Taken together with our demonstration that anti-Siglec-9 is rapidly internalised by AML cells and is not present in plasma at significant levels, these findings raise the possibility that anti-Siglec-9 antibodies could be exploited for therapeutic purposes in AML, either alone or in conjunction with other treatments, including anti-CD33 mAb-based therapy.
A characteristic feature of the CD33-related siglecs is their lineage-restricted expression pattern. For example, Siglecs-5 and -9 are mostly found on monocytes and neutrophils 6, 11, 23, 24 Siglec-7 is predominantly expressed on monocytes and NK cells 7 , Siglec-8 is restricted to eosinophils 9, 10 and Siglec-11 is expressed in tissue macrophages but is absent from circulating leukocytes 13 . This differential staining on normal blood leukocytes is consistent with the pattern of expression observed here using a diverse collection of AML samples ranging in FAB classification from M0 to M6. Thus, Siglecs-8 and -11 were not detectable on any leukemic samples analysed whereas Siglecs-5, -7, and -9 were variably present on most samples. From side-by-side comparisons of all CD33-related siglecs, it is clear that CD33 is expressed at high levels on the majority of AML samples irrespective of FAB status, (consistent with many previous studies), whereas the other CD33-related siglecs are only expressed at significant levels on subsets of CD33 + AML cells with features of myelomonocytic differentiation. An important question from a therapeutic perspective is whether Siglecs-5, -7 and -9 are expressed on the same or on separate subsets of AML cells. We demonstrated here by multiparameter labelling that all 3 siglecs were co-expressed on the same subsets, consistent with the notion that expression of these molecules is co-ordinately regulated during AML cell differentiation.
In this study, we showed that Siglec-9 was absent from all progenitors assayed, including CFU-G, CFU-M and CFU-GM and our observations, suggest that Siglecs-5 and -7 are also absent from myeloid progenitors. Therefore, it is likely that Siglecs-5, -7 and -9 are first expressed on CD33 + cells of the myelomonocytic lineages once they have lost the ability to form colonies in response to growth factors. Interestingly, expression of Siglec-9 on immature bone marrow neutrophils (defined by high side-scatter, FIG. 5 ) was weak or absent, suggesting that Siglec-9 is upregulated on these cells following their exit from the marrow. In contrast, CD33 is readily detectable on immature neutrophils and is downregulated on maturation.
The LSC is currently considered as a key target for treatment of AML 1, 25 and is found within the CD34 + CD38 − population 20, 26 . The absence of Siglec-9 from myeloid progenitors suggests that it is also likely to be absent from LSCs. Consistent with this possibility, we demonstrated that cells sorted on the basis of Siglec-9 expression did not include any AML blast colony forming cells. Therefore it is unlikely that anti-Siglec-9 mAb used alone would be capable of directly ablating the LSCs, but may be effective in targeting radioisotopes to the bone marrow for bystander toxicity to these rare cells. Anti-Siglec-9 mAb may also be useful in conjunction with anti-CD33 Abs or other therapies, for example in reducing the leukemic burden in certain cases of myelomonoblastic leukemia.
There are several potential advantages of targeting Siglec-9 for this purpose compared with Siglec-5 and Siglec-7. First, Siglec-9 had the highest expression levels as revealed by MFI values (Table 1 and FIG. 1 ). This, combined with the rapid uptake of bound Ab shown here, would be expected to lead to high levels of endocytosed Ab conjugates into leukemic cells, resulting in efficient cell death. Second, concentrations of soluble Siglec-9 in bone marrow plasma from AML patients and controls was low or undetectable, whereas Siglec-5 was present at high concentrations and could possibly neutralise a significant fraction of injected Ab. The analysis of soluble CD33 showed significant levels of this molecule also, and the elevation of both CD33 and Siglec-5 in AML samples clearly correlated with the number of circulating white blood cells in each patient. This suggests that the increased pool of soluble siglecs is leukemia cell-derived. Although the molecular properties of soluble siglecs are currently unknown, a previous report described the existence of multiple splice variants of Siglec-5, including one encoding a soluble, secreted form 24 .
In conclusion, our findings demonstrate that Siglec-9 is expressed on (myelo)monoblastic leukemias and provides a potential novel therapeutic target, especially if considered as a tailored therapy, used in conjunction with conventional cytotoxic agents or novel agents including anti-CD33 directed strategies.
References
1. Jordan C T, Guzman M L. Mechanisms controlling pathogenesis and survival of leukemic stem cells. Oncogene. 2004; 23:7178-7187.
2, Bennett j M, Catovsky D, Daniel M T, Flandrin G, Galton D A, Gralnick H R, Sultan C. Proposals for the classification of the acute leukaemias. French-American-British (FAB) co-operative group. Br J. Haematol. 1976; 33:451-458.
3. Bennett J M. World Health Organization classification of the acute leukemias and myelodysplastic syndrome. Int J Hematol. 2000; 72:131-133.
4. Varki A, Angata T. Siglecs—the Major Sub-family of I-type Lectins. Glycobiology. 2005.
5. Crocker P R. Siglecs in innate immunity. Curr Opin Pharmacol. 2005; 5:431-437,
6. Cornish A L, Freeman S, Forbes G, Ni J, Zhang M, Cepeda M, Gentz R, Augustus M, Carter K C, Crocker P R. Characterization of siglec-5, a novel glycoprotein expressed on myeloid cells related to CD33. Blood. 1998; 92:2123-2132.
7. Nicoll G, Ni J, Liu D, Klenerman P, Munday J, Dubock S, Mattei M G, Crocker P R. Identification and characterization of a novel siglec, siglec-7, expressed by human natural killer cells and monocytes. J Biol. Chem. 1999; 274:34089-34095.
8. Patel N, Brinkman-Van der Linden E C, Altmann S W, Gish K, Balasubramanian S, Timans S C, Peterson D, Bell M P, Bazan S F, Varki A, Kastelein R A. OB-BP1/Siglec-6. a leptin- and sialic acid-binding protein of the immunoglobulin superfamily. J Biol Chem. 1999; 274:22729-22738.
9. Floyd H, Ni J, Cornish A L, Zeng Z, Liu D, Carter K C, Steel J, Crocker P R. Siglec-8. A novel eosinophil-specific member of the immunoglobulin superfamily. J Biol. Chem. 2000; 275:861-866,
10. Kikly K K, Bochner B S, Freeman S D, Tan K B, Gallagher K T, D'Alessio K J, Holmes S D, Abrahamson J A, Erickson-Miller C L, Murdock P R, Tachimoto H, Schleimer R P, White J R. Identification of SAF-2, a novel siglec expressed on eosinophils, mast cells, and basophils. J Allergy Clin Immunol. 2000; 105:1093-1100.
11. Zhang J Q, Nicoll G, Jones C, Crocker P R. Siglec-9, a novel sialic acid binding member of the immunoglobulin superfamily expressed broadly on human blood leukocytes. J Biol. Chem. 2000; 275:22121-22126.
12. Munday J, Kerr S, Ni J, Cornish A L, Zhang J Q, Nicoll G, Floyd H, Mattei M G, Moore P, Liu D, Crocker P R. Identification, characterization and leucocyte expression of Siglec-10, a novel human sialic acid-binding receptor. Biochem J. 2001; 355:489-497.
13. Angata T, Kerr S C, Greaves D R, Varki N M, Crocker P R, Varki A. Cloning and characterization of human Siglec-11. A recently evolved signaling that can interact with SHP-1 and SHP-2 and is expressed by tissue macrophages, including brain microglia. J Biol. Chem. 2002; 277:24466-24474.
14. Lock K, Zhang J, Lu J, Lee S H, Crocker P R. Expression of CD33-related siglecs on human mononuclear phagocytes, monocyte-derived dendritic cells and plasmacytoid dendritic cells. Immunobiology. 2004; 209:199-207.
15. Avril T, Floyd H, Lopez F, Vivier E, Crocker P R. The membrane-proximal immunoreceptor tyrosine-based inhibitory motif is critical for the inhibitory signaling mediated by Siglecs-7 and -9, CD33-related Siglecs expressed on human monocytes and NK cells. J. Immunol. 2004; 173:6841-6849.
16. Walter R B, Raden B W, Kamikura D M, Cooper J A, Bernstein I D. Influence of CD33 expression levels and ITIM-dependent internalization on gemtuzumab ozogamicininduced cytotoxicity. Blood. 2005; 105:1295-1302.
17. Virgo P, Denning-Kendall P A, Erickson-Miller C L, Singha S, Evely R, Hows J M, Freeman S D. Identification of the CD33-related Siglec receptor, Siglec-5 (CD170), as a useful marker in both normal myelopoiesis and acute myeloid leukaemias. Br Haematol, 2003; 123:420-430.
18. Vitale C, Romagnani C, Puccetti A, Olive D, Costello R, Chiossone L, Pitto A, Bacigalupo A, Moretta L, Mingari M C. Surface expression and function of p75/AIRM-1 or CD33 in acute myeloid leukemias: engagement of CD33 induces apoptosis of leukemic cells. Prot Natl Acad Sci USA. 2001; 98:5764-5769.
19. Blair A, Hogge D E, Ailles L E, Lansdorp P M, Sutherland H J. Lack of expression of Thy-1 (CD90) on acute myeloid leukemia cells with long-term proliferative ability in vitro and in vivo. Blood. 1997; 89:3104-3112.
20. Lapidot T, Sirard C, Vormoor J, Murdoch B, Hoang T, Caceres-Cortes J, Minden M, Paterson B, Caligiuri M A, Dick J E. A cell initiating human acute myeloid leukaemia after transplantation into SCID mice. Nature. 1994; 367:645-648,
21. Andrews R G, Singer J W, Bernstein I D. Precursors of colony-forming cells in humans can be distinguished from colony-forming cells by expression of the CD33 and CD34 antigens and light scatter properties. J Exp Med. 1989; 169:1721-1731.
22. van der Velden V H, Boeckx N, Jedema I, to Marvelde J G, Hoogeveen P G, Boogaerts M, van Dongen J J. High CD33-antigen loads in peripheral blood limit the efficacy of gemtuzumab ozogamicin (Mylotarg) treatment in acute myeloid leukemia patients. Leukemia. 2004; 18:983-988.
23. Angata T, Varki A. Cloning, characterization, and phylogenetic analysis of siglec-9, a new member of the CD33-related group of siglecs. Evidence for co-evolution with sialic acid synthesis pathways. J Biol Chem. 2000; 275:22127-22135.
24. Connolly N P, Jones M, Watt S M. Human Siglec-5: tissue distribution, novel isoforms and domain specificities for sialic acid-dependent ligand interactions. Br Haematol. 2002; 119:221-238.
25. Sperr W R, Hauswirth A W, Florian S, Ohler L, Geissler K, Valent P. Human leukaemic stem cells: a novel target of therapy. Eur J Clin Invest. 2004; 34 Suppl 2:31-40.
26. Hope K J, Jin L, Dick J E. Acute myeloid leukemia originates from a hierarchy of leukemic stem cell classes that differ in self-renewal capacity. Nat. Immunol. 2004; 5:738-743.
27. Parishi, E., Draznin, J., Stoopler, E., Schuster, S. J., Poreter, D. and Sollecito, T. P. Acute myelogenous leukaemia: advances and limitations of treatment. oral Surg Oral Med Oral Pathol oral Radiol Endod 2002; 93, 257-263. | The present invention relates to agents capable of binding sialic acid-binding immunoglobulin-like lectin-9 (Siglec-9) and their use in the treatment of cell proliferation and differentiation disorders. Furthermore, the present invention provides associated pharmaceutical formulations and methods. | 77,667 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a dot-matrix printing device for calculating and accounting machines, typewriters and other printing office machines, wherein a series of striking elements in the proximity of the recording medium are movable transversely with respect to the medium and are adapted to be actuated by the armatures of corresponding electromagnets for impressing the individual dots of each character.
2. Description of the Prior Art
A series-parallel dot-matrix printing device is known wherein electromagnets actuating striking elements in the form of flexible wires have their cores fixed to the frame of the machine and their armatures have fixed to them the corresponding flexible wires, which are guided in the proximity of the recording medium by corresponding guide tubes fixed to a slide which is aligned with respect to the printing line. The slide is moved with a reciprocating motion parallel to the printing line so as to allow the ends of the wires to shift along the rows of the character matrix. The electromagnets are actuated selectively for printing the dots disposed in the rows of the matrix. In order to limit the lateral stresses exerted on the armatures of the electromagnets and on the guide tubes and to permit a sufficient and uniform action at the printing ends of the wires, the wires themselves are relatively long and are arched along a wide radius of curvature in order to accommodate the movements of the slide relative to the electromagnets. A device of this type becomes complex, bulky and costly because of the further need to connect the printing wires, which have high hardness and flexibility characteristics, individually to the armatures, of which high magnetic characteristics are required.
A series-parallel dot-matrix printing device is also known wherein the printing elements are constituted by styluses which are relatively short and rigid and fixed to cylindrical armatures of corresponding electromagnets of the hollow-core, solenoid type. The guides of the styluses and the electromagnets are fixed to a carriage shifted with a reciprocating motion parallel to the platen. This device requires a carriage and a corresponding guide structure which are rather heavy and bulky because of the need to absorb the reaction of all the armatures when printing takes place. The driving mechanism of the carriage itself has to be rather strong and therefore bulky and costly.
There is likewise known a series-parallel dot-matrix printing device wherein the striking elements are constituted by projections aligned with the printing line and formed at the ends of corresponding leaf springs in such manner as to form a comb. The springs are fixed on a carriage and are moved with a reciprocating motion parallel to the line so that each projection may print all the dots of a row of the matrix of a corresponding character. The end of each spring is adjacent the core of an electromagnet so as to be selectively attracted by the core itself and be released to print the corresponding dot, using the energy stored in the spring. A device of this type has the disadvantage of requiring electromagnets of relatively large dimensions and considerable energy for activating the electromagnets, which makes this device costly.
A dot printer operating on telegraph tape is known wherein the dots of a row of the character matrix are printed in parallel by corresponding bars connected by means of springs to a frame moved forward and backward by an actuating eccentric in front of the printing point.
Each bar can be coupled selectively to the armature of an electromagnet to be left inoperative or to be actuated for printing by the actuating eccentric. A device of this type is very complex and costly and, moreover, cannot be used advantageously in page printers because of the high construction tolerances required by the arrangement of the bars in parallel.
There is also known a serial printing device having seven flexible printing wires, wherein the free ends are vertically aligned by a resin guide. The other ends are each fixed to corresponding armatures arranged in a semi-circle and normally retained on the pole pieces of a magnetic core by the magnetic field generated by a permanent magnet and in opposition to the action of respective printing springs. The device, including the magnetic circuit, the armatures, the wires and the guides, is borne by a carriage movable transversely of the printing line. In the proximity of each armature there is moreover prearranged in the magnetic circuit a winding which, when it is energised, creates a magnetic field opposed to that of the permanent magnet, which allows the striking spring to actuate the wire for printing the dot. In this device, the recovery of the armature must be effected by the magnetic force of the permanent magnet in opposition to the action of the striking spring. The field of the permanent magnet must be fairly intense, the dimensions of the permanent magnet therefore become considerable and the energy required for printing the dot, although lower than in printing with positive actuation of the wire, is nevertheless high and requires an electronic control of high power. For these reasons, the device can find application only in those printers in which the problems of cost and size are not important.
There has also been proposed a printing device provided with a series of flexible wires which are also aligned vertically and fixed to corresponding armatures. These armatures, in turn, are retained against the pole pieces of an electromagnet by the magnetic field generated therein by the energising current of the electromagnets themselves and in opposition to the action of striking springs. By de-energising each electromagnet, the striking spring actuates the wire for printing the dot and a common cam brings the armature back into contact with the pole pieces of the electromagnet. In this device, since the electromagnets themselves must create the force necessary for retaining the armatures, with a very limited air gap, a relatively low pulse energy is required, but, since the styluses are generally in the inoperative position, the windings of the electromagnets are constantly traversed by the energising current. The dimensions of the electromagnets are therefore large and necessitate a relatively high average energising energy which requires a rather costly supply.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a simple and economic series-parallel dot printing device of small dimensions wherein the inertias of the moving parts are reduced to the maximum degree and which requires very limited consumption of energy.
According to the present invention there is provided a dot-matrix printing device for a printing office machine, wherein a series of striking elements in the proximity of the recording medium are movable transversely of the medium for printing dots in different locations and are adapted to be actuated by the armatures of corresponding electromagnets for impressing individual dots of characters, the striking elements being substantially rigid bars guided in the proximity of the recording medium by a movable guide which effects the transverse movement and each electromagnet having a fixed core and a movable armature in articulated engagement with the corresponding bar.
The invention makes it possible to reduce to the minimum the dimensions of the striking elements and the inertias of the masses having a reciprocating motion, which are limited here to the guides of the ends of the bars, and it has been possible to optimise the magnetic circuit, both from the point of view of dimensions and of efficiency and simplicity of construction.
Another object of the invention is to provide a dot printing device having low pulse energy consumption, like those devices which utilise electromagnets subject to control for actuating the printing elements, and with a low average-energy consumption, as in those devices in which the retention of the wires is achieved by the force of a permanent magnetic field.
There is therefore provided a device in accordance with the invention, wherein each armature is provided with an actuating spring which tends to move the armature away from the core of the electromagnet, means establishing a bias magnetic flux such as to keep the armature at rest in opposition to the action of the actuating spring and a winding which can be energised selectively to generate a flux opposed to the bias flux so as to allow the actuating spring to move the armature away from the core for impression of a dot, the device including a reloading member which acts on the armatures to bring them back into contact with the cores of the electromagnets.
A further object of the invention is to provide a dot printing machine having low constructive and testing cost, without effecting neither the reliability nor the printing quality.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in more detail, by way of example, with reference to the accompanying drawings, wherein:
FIG. 1 is a plan view, partly in section, of a printing device embodying the invention;
FIG. 2 is a section on the line II-II of FIG. 1;
FIG. 3 is a section on the line III--III of FIG. 1;
FIG. 4 is a section on the line IV--IV of FIG. 3;
FIG. 5 is a circuit diagram for the control of the printing device;
FIG. 6 is a diagram showing the shape or nature of a number of signals of the circuit of FIG. 5;
FIG. 7 is a diagram illustrating the printing scheme of the device;
FIG. 8 is a plan view of a modified form of the printing device;
FIG. 9 is a section on the line IX--IX of FIG. 8;
FIG. 10 is a side view from the left, partly in section, of the device of FIG. 8;
FIG. 11 is a section on the line XI--XI of FIG. 8;
FIG. 12 is a section on the line XII--XII of FIG. 11;
FIG. 13 is a diagram illustrating a detail of the device of FIG. 8 on a larger scale; and
FIG. 14 is a diagram showing various operating modes of the printing device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
According to the preferred embodiment of the invention, the printing device includes a frame 11, 411 (FIGS. 1 and 8) constituted by a base plate 14, 414 of ferromagnetic material and two vertical sides 12, 412 and 13, 413 in which a platen 15, 415 supporting a sheet of paper 16, 416 is journalled. In front of the platen 15, 415 there is arranged a horizontal slide 18, 418 which can slide in the sides 12, 412 and 13, 413 parallel to the platen 15, 415.
On the slide 18, 418 there is mounted a series of bars 20, 420 which are parallel to one another and slidable individually in guides 19, 419 (FIGS. 2 and 10) of the slide 18, 418. Each bar 20, 420 has a thickness of 0.3 mm and has one end 21, 421 tapered in the form of a wedge to define a printing tip of substantially square cross-section.
Interposed between the sheet of paper 16, 416 and the bars 20, 420 there is arranged an inked ribbon 22, 422 of known type. On the slide 18, 418 there is mounted a block 120, 520 of plastics material provided with openings 121, 521 in which the printing ends 21, 421 of the bars 20, 420 are accommodated. This block 120, 520 prevents the inked ribbon 22, 422 touching the bars 20, 420 when the latter are not actuated. Moreover, when the inked ribbon is put on, the length of ribbon interposed between the bars and the platen 15, 415 is prevented from being able to foul the said bars 20, 420.
Each bar 20, 420 is provided with a groove 23, 423 in which there is seated the upper end 24, 424 of an armature 26, 426 of a control electromagnet 27, 427.
Each armature 26, 426 is of ferromagnetic material and has its lower end 29, 429 shaped in the form of a fork which is accommodated in the base plate 14, 414. Moreover, each armature 26, 426 co-operates with a corresponding pole piece 32, 432 of the electromagnet 27, 427.
The pole pieces 32, 432 are formed as tongues of a single plate 30, 430 (FIGS. 1 and 8) of ferromagnetic material which is connected to the plate 14, 414 through blocks 33, 433 of non-magnetic material and clamping screws 34, 434 (FIGS. 2 and 10).
Between the plate 30, 430 and the plate 14, 414 there is arranged a permanent magnet 35, 435 constituted, for example, by a strip of magnetic rubber. This magnetic rubber is compressed between the said two plates, so that air gaps are avoided, and creates a constant magnetic bias flux between the plate 14, 414 and the pole pieces 32, 432 which keeps the armatures 26, 426 in contact with the pole pieces 32, 432.
Around each pole piece 32, 432 there is arranged a spool 36, 436 of plastics material. Each spool 36 (FIG. 2) is integral with a bracket having a locating peg 37 inserted in a corresponding hole 38 in the base plate 14. On each spool 36, 436 (FIGS. 2 and 10) there is wound the turns of an energising coil 40, 440 through which electric current does not normally flow and which can be energised to cancel out the bias flux in the corresponding pole piece 32, 432.
Between the spools 36, 436 and the armatures 26, 426 there is arranged a single support 42, 442 of plastics material which is fixed by means of screws 39 (shown only in FIG. 1) to the base plate 14, 414 and is provided with through holes 43, 443 for housing the ends of the pole pieces 32, 432. A series of springs 45, 445 tend to urge the armatures 26, 426 towards the platen 15, 415 in opposition to the action of the flux created by the permanent magnet 35, 435. More particularly, in the support 42 (FIGS. 1 and 2), in correspondence with each armature 26, there is formed a cylindrical recess 44 inside which there is arranged one of the springs 45, which is of spiral type and is compressed between the bottom of the recess 44 and the corresponding armature 26. Except when a winding is energised, the action of the bias flux prevails over the action of the spring.
The slide 18, 418 (FIGS. 1 and 8) and the bars 20, 420 are caused to move with a reciprocating motion in front of the platen 15, 415 by shifting means which comprise an electric motor 50, 450, a cam 58, 458 set in rotation by the motor 50, 450, and cam followers 59, 459 and 60, 460 which co-operate with the cam 58, 458 and are connected in turn to the slide 18, 418. The motor 50, 450 rotates a worm 55, 455 in mesh with a corresponding gear 56, 456 mounted rotatably on a vertical spindle 57, 457 of the frame 11, 411. The motor 50 is mounted on a third vertical side member 51 of the frame 11 and has its driving shaft 52 connected through an axially sliding flexible coupling 53 to the worm 55.
On the spindle 57, 457, fast with the gear 56, 456, is mounted the cam 58, 458, with which the cam followers 59, 459 and 60, 460 co-operate. A spiral spring 123, 523 stretched between a point 124, 524 of the cam follower 59, 459 and a point 125, 525 of the cam follower 60, 460 holds the two cam followers 59, 459 and 60, 460 constantly against the edge of the cam 58, 458 in order to take up any possible play due to wear.
The cam follower 59 is carried by a horizontal slider 62 which is guided in the side members 12 and 13 of the frame 11, and the cam follower 60 is carried by a plate 128 which is connected to the slider 62. This slider is provided with a slot 65 (FIGS. 1 and 2) into which a bottom shank 66 of the slide 18 is inserted so as to render the slider 62 and the slide 18 fast with one another.
The cam 58, 458 (FIGS. 1 and 8) is shaped in such manner as to cause the slide 18, 418 to perform an oscillation the amplitude of which is substantially equal to the width of two print characters along a printing line on the sheet of paper 16, 416. More particularly, each bar 20, 420 is adapted to print two characters (FIG. 7) dot by dot in a 7 × 5 matrix. The cam 58, 458 which controls the movement of the slide 18, 418 is shaped so that the bars 20, 420 are shifted at substantially constant speed in the spaces in which the characters are to be printed and accelerate and decelerate during the spaces between two characters. Moreover, in order also that the first and last dot of each character row may be equidistant from the other dots, the effective stroke of the bars 20, 420 is greater than the distance between the extreme dots of a row of the matrix.
Furthermore, the width of each upper part 24, 424 (FIGS. 1 and 8) of each armature 26, 426 is substantially equal to the amplitude of the said oscillation, so that each armature 26, 426 always co-operates with the same bar 20, 420 during the movements of the latter in front of the sheet of paper 16, 416.
Also fast with the gear 56, 456 (FIGS. 3 and 9) is a second worm 68, 468 which has a pitch varying along its circumference and is in mesh with the teeth of a toothed wheel 69, 469 mounted rotatably on a horizontal spindle 70, 470 supported by the side members 13, 413 and 51, 451 (FIGS. 1 and 8). The toothed wheel 69, 469 transmits the motion to the platen 15, 415 via a set of gears 72, 472.
To the worm 55, 455 there is keyed a shaft 73, 473 which is journalled in the side members 12, 412 and 13, 413 and rotates a reloading member 74, 474 comprising a cam which co-operates with the armatures 26, 426 to bring them cyclically back into contact with the corresponding pole pieces 32, 432.
A synchronising disc 76, 476 (FIGS. 4 and 12) is mounted rotatably on the vertical spindle 57, 457 and is fast with the cam 58, 458. The synchronising disc 76, 476 (FIGS. 4 and 12) is constituted by a support of plastics material on one surface of which there is deposited, for example by the printed circuit technique, a layer 79, 479 of a metallic material which is a good electric conductor, such as, for example, gold. The conductive layer defines four circular and concentric tracks 85, 485; 86, 486; 87, 487; 88, 488, with which four sensing tongues or strips 80, 480; 81, 481; 82, 482 and 83, 483, respectively, co-operate. More particularly, the track 85, 485 is entirely metallic, the tracks 86, 486 and 87, 487 have insulating zones 89, 489 and 90, 490, respectively, alternating with conducting zones 91, 491 and 92, 492, respectively, and the track 88, 488 has a single conducting zone 93, 493, while the remaining part is of insulating material. Moreover, the conducting zones 91, 491 and 92, 492 are angularly offset from one another and uniformly distributed around the respective circumferences and are also offset with respect to the conducting zone 93, 493 of the track 88, 488.
The tongue 80, 480 is constantly supplied with an electric reference voltage and the tongues 81, 481; 82, 482 and 83, 483 are adapted to detect the passage of the conducting zones 91, 491; 92, 492 and 93, 493, respectively, to send corresponding electric timing signals SP1, SP2 and SF1 to a sequencing circuit 96 (FIG. 5) of known type, for example of the type described in U.S. Pat. No. 3,951,247. More particularly, the signals SP1 and SP2 which are derived from the tongues 81 and 82, because of the rebounds to which the contact portions of the tongues may be subjected, are composed of a sequence of groups of pulses SP' (FIG. 6), while the signal SF1 output from the tongue 83 is composed of a sequence of groups of pulses SF'; each group of pulses SF' is generated every twenty groups of pulses SP'. In order to limit the sliding distances between the contacts, the conducting zones and the adjacent insulating zones are disposed around the periphery of the disc so that their width is the minimum possible compatible with the possibility of processing the signals by means of relatively simple circuits. Since the pulses SP1' and SP2' have a relatively short average duration, rebound between the contacts can be recognized as the end of the pulse itself and the resumption of contact with respect to the same conducting zone can be recognised as the beginning of a new pulse SP1' and SP2'. For the purpose of preventing erroneous interpretations of the pulses SP' and SF', the signals SP1, SP2 and SF1 are sent to flip-flops 130, 131 and 132, respectively. The flip-flops 130 and 131 are changed over by the leading edge of each group of pulses SP' and their outputs are connected to a shaping circuit 142 from which issues the shaped signal SP which is the actual timing signal of the printing dots.
The flip-flop 132, on the other hand, is changed over by the first leading edge of each group of pulses SF' and has its output connected to a shaping circuit 133 from which issues the shaped signal SF which is the actual timing signal of an elementary printing cycle (20 printing dots to a complete oscillation of the slide 18). The signals SP and SF are sent to a sequencing circuit 96, at which the information relating to the characters which are to be printed arrives on a channel 134 from a calculator 135 to which the printing device may be connected or from a keyboard 136.
The sequencing circuit 96 has outputs 137 connected to the selector electromagnets 27, 427 for selective energisation thereof and comprises a first binary counter 138 and a second binary counter 139 which are adapted to count the timing pulses of the signal SP. More particularly, the counter 138 gives a constant signal as output after five SP' pulses and the counter 139 gives an end-of-cycle signal after eighty SP' pulses, as will be described hereinafter.
The sensing tongues 80, 480; 81, 481; 82, 482 and 83, 483 are supported by a block 95, 495 (FIGS. 4 and 12) of plastics material which is pivoted on the spindle 57, 457 of the fixed frame 11, 411. The block 95 (FIGS. 1 and 4) is constantly pulled towards the side member 51 of the frame 11 by a spring 99 and has a lug 103 bearing against an adjusting screw 104 which can be screwed into, or out of, the side member 51. In this way, by screwing the screw 104 in or out, a turning action of the block 95 with respect to the side member 51 is produced, which advances or retards the picking-up of the synchronising signals by the tongues 81, 82 and 83.
The use of a sliding synchronising disc with the characteristics already described enables a transducer to be obtained which is economic and reliable and which, in contrast to optical or magnetic transducers, does not require high current inputs to be provided for the power supply of the printing device, which is therefore also of limited dimensions for this reason.
In order to bring the reloading member 74, 474, which brings the armatures 26, 426 back cyclically against the corresponding pole pieces 32, 432, into phase with the synchronising disc 76, 476, a leaf spring 106 (shown only in FIG. 1) is fixed to the vertical side member 12, 412. This spring 106 has one end 108 disposed between two flanges 109 and 110 of the shaft 74, 473 and is provided with a through hole 111 through which there extends an adjusting screw 112 screwed into the side member 12, 412. The spring 106 constantly tends to shift the shaft 73, 473 to the left.
By screwing the adjusting screw 112 in or out, axial movements of the shaft 73, 473 (FIGS. 1 and 8) and the worm 55, 455 with respect to the driving shaft 52, 452 are produced. The axial movements of the shaft 73 are possible because of the presence of the coupling 53. These axial movements cause the gear 56, 456 and the synchronising disc 76, 476 to rotate, while the cam 74, 474 is only shifted axially. Moreover, this adjustment can be made with the machine in operation in order if necessary to correct the phase of energisation of the electromagnets 27, 427 and improve the printing cycle, as will be described hereinafter.
The printing device hereinbefore described operates in the following manner. In the inoperative position, the motor 50, 450 is stationary and the slide 18, 418 is stationary at any point of its travel in front of the platen 15, 415. On the switching on of the machine, the counter 138 and 139 of the circuit 96 (FIG. 5) are zeroised in any known manner. By supplying the motor 50, 450 (FIGS. 1 and 8), the worm 55, 455 is set in rotation and consequently causes the cam 58, 458, the worm 68, 468 of varying pitch and the synchronising disc 76, 476 to rotate.
The slide 18, 418 and the bars 20, 420 thus begin to oscillate in front of the sheet of paper 16, 416. After each rotation of the worm 68 through 180°, the platen 15, 415 carries out a small rotation so as to cause the sheet 16, 416 to advance by one elementary step (i.e., the pitch between dots in the matrix) which, in accordance with current standards, is about 0.38 mm.
The sensing tongues 81, 481; 82, 482 and 83, 483 detect the passage of the conducting zones 91, 491; 92, 492 and 93, 493, respectively, sending corresponding electric timing signals SP and SF to the sequencing circuit 96 (FIG. 5) which controls the energisation of the electromagnets 27, 427.
After counting five timing pulses SP', the counter 138 generates a signal enabling printing true and proper. The first pulse SF' which arrives at the sequencing circuit 96 after the enabling signal of the counter 138 gives the start for the printing cycle.
It is to be noted that the synchronising disc 76, 476 (FIGS. 3 and 11), the worm 68, 468 of varying pitch and the cam 58, 458 are offset from one another so that the pulses SF' are generated in coincidence with the advance of the platen 15, 415 and when the slide 18, 418 is located shifted completely to the right (FIGS. 1 and 8). The first row of dots is therefore printed from right to left.
As has been seen, each bar 20, 420 is adapted to print two print characters for each printing line and, therefore, all the 70 dots of the two 7 × 5 matrices must be covered in successive passes, the inked ribbon 22, 422 being impressed only when a predetermined dot is to be printed on the basis of a predetermined code.
Thus, for example, if a bar 20, 420 is to print the numerals one and two (FIG. 7), during the first pass from right to left it imprints the 2nd, 3rd, 4th and 8th dots, while during the second pass, from left to right, it imprints the 12th, 13th, 16th and 20th dots after the paper has been advanced by one elementary step.
Referring only to the device of FIGS. 1 to 7, after the second pass and before the third a second phasing pulse SF' is generated.
After seven passes the bar 20 completes the printing of two characters, but the slide continues to oscillate at least until the completion of the eighth pass. After eighty pulses SP', in fact, the counter 139 generates an end-of-cycle signal which arrests the motor 50, unless an order to print a following line of characters arrives at the sequencing circuit 96 from the calculator 135 or from the keyboard 136.
On sending the end-of-cycle signal after the eightieth pulse SP' from the commencement of the printing, before the motor stops it carries out, owing to inertia, a further small rotation which causes another pulse SF' to be generated and the slide 18 to stop at any point between the ninth and tenth passes. As a rule, the slide 18 stops at least five positions before the completion of the tenth pass. In this way, when the order for another printing cycle is given, a fresh pulse SF' is generated after the counter 138 has generated the enabling signal, having already counted five pulses SP'. By this expedient, while the slide 18 performs three idle passes, line-spacing equal to three elementary advances of the paper 16 is obtained between two successive lines of characters.
The cam 58 is shaped so as to cause the slide 18 to shift at constant speed when the bars 20 are located in correspondence with the printing points and to cause it to accelerate and decelerate during its movement between one character and the other, so that the time taken by the bars 20 to bring themselves from the 5th to the 8th column of the matrices may be equal to the unit time which is taken for the movement between two adjacent columns. Moreover, in this way, the conducting zones 91 and 92 of the synchronising disc 76 are also uniformly distributed along the tracks 86 and 87.
The printing of a dot takes place in the following manner. Referring to the device according to the two embodiments, the armatures 26, 426 are held when inoperative or at rest with a force of about 100 g. against the corresponding pole pieces 32, 432 by the effect of the bias magnetic field created by the strip 35, 435 of magnetic rubber and in opposition to the force of the springs 45, 445 which is equal to about 70 g.
The corresponding selector magnet 27, 427 is now energised by means of a current pulse of about 100 mA for 1 msec. at 18 v. in the coil 40, 440. This creates in the corresponding pole piece 32, 432 a magnetic flux which is opposed to that of the previously existing field, in such manner as to reduce the net magnetic force below the force of the springs 45, 445. The spring 45, 455 can thus urge the armature 26, 426 towards the platen 15, 415, causing it to rotate with respect to its pivoting seat 31, 431. As soon as the armature 26, 426 separates from the pole piece 32, 432, an air gap is formed which further reduces the residual magnetic force and enables the spring 45, 445 to accelerate the armature 26, 426 strongly towards the platen 15, 415.
In this way, the bar 20, 420 is also moved at high speed towards the platen 15, 415 and a dot of substantially square section is imprinted on the sheet of paper 16, 416. Once the printing of the dot has been effected, the cam 74, 474 brings the armature 26, 426 back cyclically into contact with the pole piece 32, 432.
In this cyclic system with mechanical recovery of the armatures, the energisation of the electromagnet 27, 427 which begins substantially at the same instant when the timing pulses are picked up on the synchronising disc 76, 476 must be in phase with the rotation of the cam 74, 474. In order to optimise the printing cycle, this is effected with the machine in operation by screwing the screw 112 into or out of the side member 12, as has been seen hereinbefore.
More precisely, referring to FIG. 14, on a space-time graph v of the cam 74, 474 and between the instant when the command of energisation is given to the electromagnets 27, 427 and the instant when the armatures 26, 426 are close to the platen 15, 415, a fixed time tr of about 2.3 msec. elapses due to the inductances of the magnetic circuit, the mechanical characteristics of the springs 45, 445 and the inertia of the armatures 26, 426. The command of energisation is therefore given at an instant to which is a time tr in advance with respect to the instant t1 when the cam 74, 474 is beyond the path of the armatures 26, 426 towards the platen 15, 415. Moreover, to enable the bars 20, 420 to imprint a dot correctly on the sheet of paper 16, 416, the recovery of the armatures 26, 426 (instant t2) must begin at least after a time ta of the order of about 1.5 msec. With times tr and ts close to the values already given, the nominal printing cycle T becomes about 6.25 msec., which corresponds to a printing speed of two lines per second for the printing system used.
During the operation of the device, the supply conditions of the electric motor 50, 450 may vary and, consequently, the speed of rotation of the shaft 52, 452 may also vary, and therefore that of the cam 74, 474.
The variations in speed of the motor 50, 450, acting on the cycle T and not on the times tr and ta, alter the conditions of release and recovery of the armatures 26, 426. More particularly, for a lower limit value, corresponding to a curve v", the instant at which the bar 20, 420 touches the platen coincides with the instant t1" at which the cam 74, 474 would tend to arrest the bar. Below this value, the armature 26, 426 would beat against the cam 74, 474 before this has brought itself beyond the path of the armatures 26, 426, thereby preventing the printing of the dot. On the other hand, the speed cannot rise above a value (curve v') such that the instant t2' arrives before the time (tr + ta) has elapsed from the command of energisation of the electromagnets 27, 427, because in this case the armatures 26, 426 would be brought back towards the corresponding pole pieces before the printing of the dot on the sheet of paper 16, 416 has been completed.
In the programming of the nominal speed v, account is therefore taken of a safety margin in order to define the range v' and v" within which the speed will always be satisfactory for obtaining a good printing quality.
On the other hand, the times (tr and ta), which are optimized for a prototype, may assume values different from one to another in the mass production units. Above all it is desired to have in mass production wide margin of tolerances. Accurate phasing is therefore advisable on each individual unit to take account of the specific characteristics of the unit itself. This can easily be done, with the device in operation, by varying the speed of the motor and thereafter controlling the regularity of the printing in the following manner.
First, the motor 50, 450 is brought to the lower limit speed which, for example, may be 10% lower than the nominal speed, and the screw 112 is operated on so that, with good operation, the picking-up of the timing pulses is advanced to the maximum with respect to the phase of the cam 74, 474, so that the striking occurs at the instant t1", precisely at a time tr after the energization of the selector electromagnets 27, 427. Then the motor 50, 450 is brought to the highest speed, which may be, for example, 10% higher than the nominal speed, and it is checked that the instant t2' occurs after the time (tr + ta) has elapsed. It is therefore clear that because of this adjustment or setting-up neither further gradual adjustments in the stationary state on the same unit, nor the use of special test equipment are necessary.
In addition to the phasing already described, the device enables phasing to be effected easily of the instant of energization of the electromagnets 27, 427 with respect to the position of the slide 18, 418 along the printing line, for obtaining a good printing quality with the zig-zag method of printing already described. In fact, if the command to the bars 20, 420 is given when they have not yet reached the nominal printing position or have already gone beyond it, the dots of the rows printed in the passes from right to left will be disposed to the right or to the left, respectively, of the theoretical position, and, conversely, the dots of the rows printed in the passes from left to right will be disposed to the left or to the right, respectively, of the theoretical position, thus giving rise to staggering of the dots in the same column of the matrix.
For this phasing, the adjusting screw 104 is operated on to shift the tongues 80, 480; 81, 481; 82, 482 and 83, 483 with respect to the synchronising disc 76, 476, thus advancing or retarding in this way the picking-up of the timing signals until such time as the dots in the same column are visibly aligned. This adjustment can therefore also be made with the machine in operation, thus permitting an immediate check by the operator on the result of the printing.
The printing device illustrated in FIGS. 8 to 13 has the following modifications with respect to the printing device illustrated in FIGS. 1 to 7.
Each bar 420 (FIGS. 8 and 13) has a front end 550 (remote from the platen) guided in a corresponding slot 551 in the support 442, so that the bars 420, instead of shifting in parallel together with the slide 418, oscillate about their pivoting point constituted by the slot 551, thus describing a circular arc with their printing ends 421. This modification with respect to the device of FIG. 1 enables the dimensions of the upper ends 424 of the armatures 426 which co-operate with the grooves 423 of the bars 420 to be reduced.
In the device of FIG. 1, in fact, the printing tip 21 of each bar 20 is at a distance of 5.1 mm from the adjacent printing tip, since in accordance with current standards with a step equal to 10 characters per inch a print character has a width of about 1.757 mm and the distance between one character and another is about 0.793 mm. The pitch between two adjacent armatures 26 is 5.1 mm. Moreover, since each printing point is at a distance of 0.364 mm from the adjacent point, the useful stroke of each printing tip 21 of the bars 20, and therefore also of the slide 18 in front of the platen 15, is about 4.004 mm and the actual stroke which, for the reasons already described, is greater than the distance between the extreme dots of a row of the dot matrix, is about 4.3 mm. Consequently, in order to be able to co-operate always with the same bar 20, each armature 26 must have its upper end 24 at least 4.6 mm wide. It is moreover expedient that this end 24 of the armatures 26 be wider than the length of the actual stroke of the bars 20. In fact, their width is 4.8 mm. In this way, the nominal clearance between one armature 26 and the adjacent one comes out at 0.3 mm. Consequently, the tolerances, both at the pivoting seats 31 and at the armatures 26, have to be rather fine.
In the device of FIG. 8, on the other hand, while the excursion which the printing tip 421 must perform in front of the platen 415 is still 4.004 mm, it is sufficient that the upper end 424 of each armature 426 be 3.5 mm wide. In this way, the armature 426 being still pitched at intervals of 5.1 mm, the ends 424 have a clearance of 1.6 mm between them and therefore the tolerances may be relaxed.
It is obvious that, in order to reduce the dimensions of the armatures 426 further, they could be placed closer to the pivoting point 551, but, since the rise of the circular arc described by the printing end 421 decreases with the approach of the armature 426 to the end 421, the armatures 426 are disposed at an intermediate point so that the rise may be contained within acceptable and practically negligible levels if these are related to the distance at rest between the printing end 421 and the platen 415. It is obvious that this rise could also be completely nullified by shaping the armature 424 so that it is curved and has a central valley or hollow corresponding to the value of the rise which it is desired to take up.
In order to permit the bars 420 to oscillate, the guides 419 of the slide 418 are slightly wider than the bars 420 themselves. The play which is created between the guide 419 and the bar 420 is, however, negligible when the bars are inclined, whereas it would be excessive when the bars are in the intermediate positions. Since, however, with the printing system adopted, the points intermediate between two characters are never printed on, there is no disadvantage because of this play.
In the modified construction of FIG. 8, instead of the springs 445 being of spiral type, they are constituted by a plurality of leaf springs formed from a single metal plate 560 fixed at the bottom to the support 442 by means of a clamping element 561 of plastics material (FIGS. 8 and 10).
The armatures 426 are also modified with respect to the armatures 26. More particularly, on each of these there is formed a horizontal front projection 570 and a projecting element 572, which is also at the front. The horizontal projection 570 has an end 571 in the form of a spherical cap which normally co-operates with the corresponding pole piece 432. On the projecting elements 572, in turn, there bear the terminal portions of the springs 445.
The use of a spherical surface which contacts the pole piece 432 enables an air gap which is very limited (of the order of 0.02 mm) and constant to be obtained even if the armature 426 is not perfectly aligned, because of the clearance with which it is pivoted, with a negligible air gap, in its seat 431. Moreover, the area of contact being limited, the specific force between the cap 571 and the pole piece 432 becomes very high. This causes any possible foreign particles or traces of lubricant to remain outside the air gap and not affect the reluctance of the magnetic circuit.
The support 442 is also modified with respect to the corresponding support 42. More particularly, in order to receive the ends 571 of the individual armatures 426, a recess 580 is formed in correspondence with each of these. The aim of this recess 580 is to prevent contaminants such as oil, dust or paper fibres, interposing themselves between the armature and the pole piece and thus cause deterioration of the working conditions.
Inside the support 442 and over the entire length thereof there is arranged a non-magnetic metal plate 581 provided with slots 582 in which hooked shanks 583 of each spool 436 are engaged.
As has been seen hereinbefore, an elementary printing cycle T (printing of a dot) has a duration of about 6.25 msec, which corresponds to a frequency of 160 Hz. Therefore, the shaft 73 and the cam 74 rotate under normal conditions at 9,600 revolutions per minute. In order to deaden the noise due to the impact between the cam 74 and the armature 26 during the recovery of the latter, the cam 74 is constituted by an eccentric and, in correspondence with each armature 26, there is arranged slidably in a groove a ring 190 (FIGS. 1 and 2) of plastics material or sufficiently hard rubber. These rings balance the forces on the various armtures 26 and, by rotating in their respective grooves, act so that throughout the period during which the eccentrics 74 maintain the armatures 26 in contact they limit the wear between the parts in reciprocal movement. As a modification, for the purpose of reducing the speed of rotation of the armature reloading member, in particular on account of the problems of balancing that this requires, the cam 474 (FIGS. 8 and 10) has a profile comprising three lobes offset by 120° from one another. Both the speed of rotation of the shaft 473 and that of the motor 450 are thus reduced in the ratio of 3 to 1. Moreover, in order to reduce the overall dimensions of the device, the motor 450 is fixed to the side member 412 below the platen 415. In this case, in order to reduce the noise due to the reloading of the armatures, between the cam 474 and the armatures 426 there are interposed leaf springs 575 formed from a single metal plate 576 which is fixed to a bent lower portion 577 of the frame 411 by means of a clamping element 578 of plastics material. Each upper end 574 of the leaf springs 575 acts on a spherical cap 573 which is formed on the armature 426 opposite the horizontal projection 570, at the rear of the armature.
For the purpose of reducing the time taken to carry out line-spacing between two lines of characters and the wear between the worm and the corresponding pin, the worm 468 (FIGS. 9 and 11) is formed on the periphery of a drum 580 of plastics material and inside which there is formed the profile of the cam 458. Pins 581 of the wheel 469 co-operate with the grooved profile of the worm 468. This profile 468 is formed so that after each 180° of rotation of the drum 580, simultaneously with the reversal of the movement of the slide 418, the platen 415 advances by one elementary step, equal to 0.38 mm, during the first seven passes, and advances by three elementary steps, equal to 1.14 mm, when the slide 418 has completed the seventh pass and is about to perform the eighth (see also FIG. 7). In this way, the sliding for each character between the surface of the worm 468 and the pin 581 is reduced in the ratio of 5 to 1 with respect to the corresponding sliding between the surface of the worm 68 and the teeth of the gear 69. Moreover, the time taken to carry out the line-spacing is substantially equal to that taken for printing a line of dots. To do this, the system for detecting the timing signals is partly modified. More particularly, instead of the pulses SF' being generated every twenty printing dots, they are generated only at the beginning of a line of characters. In fact, the tongue 483 is normally kept spaced from the synchronising disc 476 by a block 590 arranged on the block 495. The tongue 483 is urged cyclically towards the disc 476 by a slider 591 slidable inside the block 495 and controlled in turn by a bail lever 592. The lever 592 is pivoted on a fixed pin 594 (see also FIG. 12) and has an arm 593 in contact with the slider 591 and an arm 595 in contact with the outer profile 596 of the wheel 469. A spring 597 ensures contact between the lever 592 and the wheel 469.
The outer profile 596 of the wheel 469 is shaped in such manner as to shift the lever 592 cyclically clockwise (FIG. 11) to bring the slider 591 upward and thus bring the tongue 483 against the corresponding track 488 of the disc 476 only at the beginning of each line of characters. As has already been described, the synchronising disc 76 for picking up the twenty timing pulses SP', which produce the printing of the twenty dots of an elementary printing cycle, has on its tracks 86 and 87 ten conducting zones 91 and 92, respectively, for each track and contact of each of these conducting zones with the corresponding tongues 81 and 82 causes the generation of a timing pulse SP'. Apart from the advantages of easy processing of shaped signals, this also entails reducing to the minimum the dimensions of the disc 76 and the unit sliding effects between the individual tongues and the conducting zones 91 and 92.
The separation of the picking-up of the timing signals on two different members (tongues 81 and 82), however, requires careful precision in the arrangement of the tongues 81 and 82 with respect to the synchronising disc 76. Mutual misalignment thereof, in fact, would lead to a phase difference between the picking-up of the pulses of the track 86 and those of the track 87, and a consequent inequality between the distances between the dots of the matrix. Moreover, this could limit the tolerance in the phasing between the synchronising disc 76 and the recovery member 74 for the armatures 26.
In order to obviate this possible drawback, the synchronising disc 476 presents the following modifications. In each of the tracks 486 and 487 there are twenty conducting zones 491 and 492, so that at each revolution of the disc 476 twenty pulses SP1' and twenty pulses SP2' are generated. The signals SP1 and SP2 are sent in one case to the set input and in the other case to the reset input of a single flip-flop which has an output connected directly to the sequencing circuit 96. The pulses SP1' act in this way as actual timing pulses, while the pulses SP2', which are out of phase with respect to the pulses SP1', serve only to reset the pulses SP1'. In this way, the timing pulses SP', which correspond to the pulses SP1', are picked up by a single element (tongue 482) and are all equidistant. Moreover, this enables a second flip-flop and a shaping circuit to be saved, compared with the device of FIGS. 1 to 7.
Moreover, as another modification, the block 495 is fixed to the frame 411 by means of a clamping screw 495a which engages a slot 598 in the block 495 itself to clamp it removably with respect to the frame 411. By slackening the screw 597, the block 495 can be rotated manually with respect to the frame 411 to advance or retard the picking-up of the timing signals by the tongues 481, 482 and 483 for the purposes seen hereinbefore.
Finally, as a last modification, the profile of the cam 458 is modified with respect to that of the cam 58. In fact, as has been seen, the cam 58 is shaped in such manner as to cause the slide 18 to move at constant speed when the bars 20 are in correspondence with the printing points and cause it to accelerate and decelerate during the movement between one character and the other. In practice, this causes each dot to be printed on the fly, while the slide 18 advances with a continuous motion in front of the sheet of paper 16. According to the modification, on the other hand, the cam 458 is shaped in such manner as to cause the slide 418 to move step by step in front of the platen 415, so that the slide 418 itself is stationary when the bars 420 are actuated.
For the protection of all the bars 420, a cover 599 (FIG. 10) of plastics material is provided, this being arranged above the support 442.
It is moreover to be noted that in order to reduce the cost of the device the armatures 26, 426 are produced by sintering powders of ferromagnetic materials, for example by the method described in the U.S. Pat. No. 3,020,589.
It is obvious that other modifications or additions of parts may be made in the printing devices hereinbefore described without departing from the scope of the claims. For example, both the synchronising disc and the cam which controls the movement of the slide 18, 418 may be keyed directly on the shaft 73, 473 which carries the recovery member for the armatures 26, 426, thus eliminating the coupling between the worm 55, 455 and the gear 56, 456.
The structure of the electromagnets is not limited by the using of particular printing elements. In particular these elements may be flexible wires instead of rigid bars. Moreover, with respect to the synchronizing signals and to the mechanism for the movements between the printing elements and the recording medium, the invention is not limited to the using in impact printers, but it may applied to non-impact printers as in the electrothermal printing unit of the U.S. Pat. No. 3,951,247, which is incorporated herein as reference. In this last case, instead of using as printing elements the bars actuated by electromagnets, it may be used a corresponding plurality of resistors carried by a corresponding support member. | A dot-matrix printing device for a printing office machine, comprising a series of striking bars in the proximity of the recording medium movable transversely of the medium for printing dots in different locations. The bars are adapted to be actuated by the armatures of corresponding electromagnets for impressing individual dots of characters. The striking bars are guided in the proximity of the recording medium by a movable guide which effects the transverse movement and each electromagnet has a fixed core and a movable armature in articulated engagement with the corresponding bar. Each armature is provided with an actuating spring which tends to move the armature away from the core of the electromagnet. A permanently magnetized rubber establishes a bias magnetic flux such as to keep the armatures at rest in opposition to the action of the actuating springs and a plurality of windings can be energized selectively to generate a flux opposed to the bias flux so as to allow the actuating springs to move the armatures away from the cores for impression of the dots. The device further includes a reloading member which acts on the armatures to bring them back into contact with the cores of the electromagnets. | 50,500 |
CLAIM OF PRIORITY
[0001] The present patent application claims the priority benefit of the filing date of U.S. provisional application No. 60/921,213 filed Apr. 1, 2007, the entire content of which is incorporated herein by reference.
TECHNICAL FIELD
[0002] This disclosure relates generally to menu presentation generation for computational machines to facilitate navigation during use of an application.
COPYRIGHT NOTICE/PERMISSION
[0003] A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever. The following notice applies to the software and data as described below and in the drawing hereto: Copyright ©2007, SAP, AG, All Rights Reserved.
BACKGROUND
[0004] Users of an application can often access the application under different contexts. For example a user can access an application by using a desktop platform, but at a different occasion, may access the same application while using a mobile platform such as a handheld computational machine, which may cause a difficulty for the user.
[0005] The menu method of accessing the application can differ significantly between the platforms, and indeed, can even differ among the first two, and a third platform such as an audio-only platform.
DESCRIPTION OF DRAWINGS
[0006] The disclosure is illustrated by way of example and not limited to the figures of the accompanying drawings, in which like references may indicate similar elements and in which:
[0007] FIG. 1 illustrates a mapping between a conventional navigational list and a navigational list according to an embodiment.
[0008] FIG. 2 illustrates various presentations for migrating across different hardware platforms according to an embodiment.
[0009] FIG. 3 illustrates a software platform for the generation of a menu presentation relative to a given menu orientation according to an embodiment.
[0010] FIG. 4 illustrates a time-dependent navigational tool for a radiant-energy menu presentation according to an embodiment.
[0011] FIG. 5 illustrates a hand-held platform for accessing any of the menu presentation embodiments.
[0012] FIG. 6 illustrates a hand-held platform for accessing any of the menu presentation embodiments.
[0013] FIG. 7 illustrates a hand-held platform for accessing any of the menu presentation embodiments.
[0014] FIG. 8 is a diagram of a method for presenting a navigational control record of a browsing session according to an example embodiment of the disclosure.
[0015] FIG. 9 is a block diagram of a machine in the illustrative form of a computer system within which a set of instructions, for causing the machine to perform any one or more of the methodologies discussed herein, may be executed.
[0016] FIG. 10 is a diagram of an architecture according to various embodiments.
[0017] FIG. 11 displays two different conventional presentations that can occur between two platforms that present the same application.
DETAILED DESCRIPTION
[0018] The following description contains examples and embodiments that are not limiting in scope. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of an embodiment of the present disclosure. It will be evident, however, to one skilled in the art that the present disclosure may be practiced without these specific details.
[0019] A desktop platform may have an abundance of visual/graphical display area to present a menu with useful navigational targets, but a handheld platform will likely have comparatively limited visual/graphical display area to present the same navigational targets.
[0020] With a visual/graphical presentation for example, menu presentations can have a top-accessible origination point with a menu that opens downwardly, a bottom-accessible origination point with a menu that opens upwardly, or even a sideways-opening menu, among others. With a visual/graphical presentation, these differing presentations can occur even with a single standard software package.
[0021] A difficulty for the user can arise in the hand-held environment, such as a delivery worker who is returning to his vehicle and at the same time accessing an application with his hand-held platform while walking along a busy thoroughfare. The worker desires to focus his viewing upon traffic, both vehicular and pedestrian, but at the same time access the application within the hand-held platform.
[0022] FIG. 11 displays two different conventional presentations that can occur between two platforms that present the same application.
[0023] A top-down menu presentation 1101 includes the origination point 1110 such as a menu bar. It may include a first navigational target 1114 that represents a data-access location (DAL) that was first accessed. Several other navigational targets are depicted, such as a second navigational target 1116 that represents a DAL, an intermediate navigational target 1118 that represents a DAL, and a last navigational target 1122 that represents a DAL. A difficulty for a user such as a delivery worker who is accessing the application from a hand-held platform and who may be distracted by traffic, is that he may want to access the DAL represented by the first navigational target 1114 , but he may be positioned starting at the origination point 1110 in the menu. Consequently, the delivery worker may have to push a navigational button several times to reach the DAL represented by the first navigational target 1114 , which may require diverting his eyes significantly long from observing traffic.
[0024] A similar problem exists with a bottom-up menu presentation 1102 where the user reaches the desired DAL by visually scanning the menu display. The same software may be used for the presentation 1101 , but the user has migrated to a different hardware platform. The presentation 1102 includes the origination point 1130 such as a menu bar. It also includes a first navigational target 1134 that represents a DAL that was first accessed. Similarly to the top-down menu presentation 1101 , the bottom-up menu presentation 1102 may display several other navigational targets, such as a second navigational target 1136 that represents a DAL, an intermediate navigational target 1138 that represents a DAL, and a last navigational target 1142 that represents the last-accessed DAL. The difficulty for a delivery worker is similar to that depicted with the top-down menu presentation 1101 as for this bottom-up menu presentation 1102 . The delivery worker may want to access the DAL represented by the first navigational target 1134 , but he may be positioned in the menu at the origination point 1130 . Consequently, the delivery worker may have to push a navigational button several times to reach the DAL represented by the first navigational target 1134 , which may require diverting his eyes significantly long from observing traffic if the navigation tasks requires him to visually track the results of his navigational behavior.
[0025] Terminology
[0026] The following terminology is exemplary but not limiting. A “selectable target” is synonymous with a menu element that can be selected by a user. A “data-access location” (DAL) is accessed by using a selectable target.
[0027] A “navigational target” is an accessible target on a presentation of a menu that directs the user to a different location within a given application, or to a different application.
[0028] An “object target” is a selectable target on a presentation of a menu that can import or export a file, or a data structure that is stored in memory.
[0029] In the various embodiments disclosed herein, there are visual menu presentations, audio menu presentations, tactile menu presentations, and combinations thereof.
[0030] FIG. 1 illustrates a comparison between a conventional navigational list and a navigational list that is generated as a menu presentation according to an embodiment. A bottom-up menu presentation 100 , as a conventional menu orientation, includes the origination point 110 such as a menu bar. It may also include the first navigational target 112 that represents a data-access location that was first accessed. The bottom-up menu presentation 100 may display several other navigational targets, such as a second navigational target 114 that represents a DAL, an intermediate navigational target 116 that represents a DAL, and the second to last navigational target 118 that represents a DAL as well as the last navigational target 120 that represents the last-accessed DAL. Again, the difficulty is that a user may want to access the DAL represented by the first navigational target 112 , but the user may be positioned in the menu at the origination point 110 at the onset of starting to navigate to DAL 112 . Consequently, the user may have to push a navigational button several times to reach the DAL represented by the first navigational target 112 , which may require diverting his eyes significantly long from observing traffic in order to ensure that he reaches the desired DAL by visually scanning the menu display.
[0031] The bottom-up menu presentation 101 for a given computational machine, according to an embodiment, represents a transformation of the bottom-up menu presentation 100 , such that it is a generation of a menu presentation relative to the given menu presentation 101 . This embodiment includes the origination point 111 such as a menu bar. It may also include the first navigational target 113 that represents a DAL that was first accessed. The bottom-up menu presentation 101 may display several other navigational targets, such as a second navigational target 115 that represents a DAL, an intermediate navigational target 117 that represents a DAL, and the second to last navigational target 119 that represents a DAL as well as the last navigational target 121 that represents the last-accessed DAL.
[0032] Where the user likely wants to navigate from the origination point 111 to the first navigational target 113 , only a single, generic command is required such as a single button push, and the first navigational target 113 is accessible accordingly at the onset of starting to navigate to DAL 112 and subsequently reached immediately as a result of the single button push. The computational machine presentation therefore re-arranges the first navigational target 113 in a spatial relationship to a presentation location that is nearer the origination point 111 . Consequently, the user need not divert his attention from traffic, but with haptic knowledge of the menu presentation can navigate more easily from the origination point 111 to the first navigational target 113 .
[0033] The “first navigational target 113” may be a most likely or most frequently accessed navigational target 113 to be first accessed when the user has returned to the platform to access data. The most frequently accessed navigational target 113 may also be referred to as a most frequently visited data-access location. For example, a delivery worker may have a queue of deliveries that are electronically stored in data-access locations, and after delivering to a customer, he accesses the application from a hand-held device, and navigates to the first navigational target 113 . Consequently the DAL, accessed at the first navigational target 113 , allows the delivery worker to immediately and with a single action, ascertain his next customer in the delivery queue. Further, the single action does not require diversion of his attention. In a method embodiment, the method includes compiling a list of visited data-access locations. In an embodiment, however, a method may further include monitoring a selection likelihood of a first selectable target such as the first navigational target 113 and a second selectable target such as the second navigational target 115 , and when the second selectable target becomes more likely to be selected than the first selectable target, the method further includes re-arranging the second selectable target to a presentation nearer the origination point, and re-arranging the first selectable target to a presentation less near the origination point than the second selectable target. In other words, the second selectable target is presented as a prominent selectable target or a most recently visited data-access location. In an embodiment, re-arranging the order of selectable targets may occur consistently for all platforms that may be available for use of the same application.
[0034] It can be seen that another method embodiment includes a second selectable target and a third selectable target, the method including, where re-arranging the second selectable target because it is less likely to be selected first, to a presentation nearer the origination point, but re-arranging the third selectable target less likely to be selected second, to a presentation nearer the origination point, but the second selectable target is re-arranged to a presentation nearer the origination point than the third selectable target.
[0035] FIG. 2 illustrates various presentations 200 for migrating across different hardware platforms (also referred to as “hardware contexts”), according to an embodiment.
[0036] A bottom-up menu presentation 201 shows an origination point 211 and then DALs named ORANGE 213 , APPLE 215 , BANANA 217 , and KIWI 219 . These DALs are rearranged according to likelihood of access from the origination point 211 , based upon frequency of use, or based upon likelihood of being used next according to an embodiment.
[0037] A top-down menu presentation 203 shows an origination point 231 and then DALs named ORANGE 233 , APPLE 235 , BANANA 237 , and KIWI 239 . These DALs are rearranged according to likelihood of access from the origination point 231 , based upon frequency of use, or based upon likelihood of being used next according to an embodiment. In an embodiment, a user has migrated between two hardware platforms, which display the respective menu presentations, one being bottom-up 201 and the other being top-down 203 . Because the presentation style persists between the two hardware platforms, the user experiences an ease of use despite migrating between the two respective hardware platforms.
[0038] A left-to-right sideways menu presentation 205 shows an origination point 251 and then DALs named ORANGE 253 , APPLE 255 , BANANA 257 , and KIWI 259 . These DALs are rearranged according to likelihood of access from the origination point 251 , based upon frequency of use, or based upon likelihood of being used next according to an embodiment. In an embodiment, a user has migrated between two hardware platforms, which display the respective menu presentations, one being bottom-up 201 and the other being left-to right sideways 205 . The user experiences an ease of use despite migrating between the two respective hardware platforms.
[0039] A right-to-left sideways menu presentation 207 shows an origination point 271 and then DALs named ORANGE 273 , APPLE 275 , BANANA 277 , and KIWI 279 . These DALs are rearranged according to likelihood of access from the origination point 271 , based upon frequency of use, or based upon likelihood of being used next according to an embodiment. In an embodiment, a user has migrated between two hardware platforms, which display the respective menu presentations, one being bottom-up 201 and the other being right-to-left sideways 207 . The user experiences an ease of use despite migrating between the two respective hardware platforms.
[0040] FIG. 3 illustrates a software platform 300 for the generation of a menu presentation relative to a given menu orientation according to an embodiment. In an embodiment, several different domains may be used to access the software platform 300 . In an embodiment, several different hardware contexts may be used to access the software platform 300 . Specialized hardware contexts may use only a portion of the software platform 300 .
[0041] In an embodiment, a user may invoke the software platform 300 , and a user domain is recognized thereby. In an embodiment a user FIRST DOMAIN 310 represents a recognition capability of the software platform 300 . Where a user may migrate between hardware contexts, the user may still access the same data from the user FIRST DOMAIN 310 , although he may be using a different hardware context. Other domains are represented, including a user SECOND DOMAIN 312 and so on until a user n th DOMAIN 314 . In an embodiment a given user domain may be an internet-based source through which a user is operating. In an embodiment a given user domain may be a telephonic communications-based source through which a user is operating.
[0042] A user may also invoke the software platform 300 by a subsequent hardware context 320 , such as a mobile platform (mobile machine), a desktop platform (desktop machine), a laptop platform (laptop machine), or other platforms.
[0043] In an embodiment, the user domain and the hardware platform are recognized by the software platform 300 , and the software platform 300 adapts to the combination for a configuration that is useful for the specific user, but that may adapt for an alternative user.
[0044] The software platform 300 also recognizes a relationship, in concert with the given domain and hardware context. In an embodiment, a RELATIONSHIP 0 th 330 is recognized such as a specific customer with specific needs. In an embodiment, the RELATIONSHIP 0 th 330 represents a default relationship, such as a most likely relationship for a given configuration of the software platform 300 . In an example embodiment of the delivery person, the relationship may invoke a specialized subset of a given application, such that the specialized subset has been configured to meet the most useful needs of the delivery person as the user of the software platform 300 . At another time, the delivery person may invoke the software platform 300 that requires a different relationship. For example in the field, the delivery person RELATIONSHIP 0 th 330 maybe useful, but in a reporting meeting such as a headquarters, a different relationship is more useful.
[0045] In an example embodiment, the software platform 300 is configured for private individual use such as a wireless telephone user. The RELATIONSHIP 1 st 332 may be configured for the wireless telephone user, and the wireless telephone user may be accessing an email attachment that requires the execution of a software program such as a word processor. Accordingly the RELATIONSHIP 1 st 332 may allow the wireless telephone user to have an efficient session while opening and navigating through the word processor. For example, where the RELATIONSHIP 1 ST 332 is a wireless telephone network, a user such as a delivery person may migrate from a wireless first hardware context to a desktop (subsequent) hardware context 320 and continue working on a task. Accordingly, the bottom-up presentation may be emulated within the desktop (subsequent) hardware context 320 that matches the presentation that was in the wireless telephone first hardware context 320 .
[0046] Other relationships are also depicted, including a RELATIONSHIP 2 nd 334 , a RELATIONSHIP 3 rd 338 , and so on until a RELATIONSHIP n th 340 . In an embodiment, the various relationships may represent various different customers who have distinct and specific customer needs the software platform may be designed to handle.
[0047] In an embodiment, the RELATIONSHIP 2 nd 334 depicts sub-relationships, including a RELATIONSHIP 2.1 st 333 , a RELATIONSHIP 2.2 nd 335 , and so on until a RELATIONSHIP 2.n th 337 . In an embodiment, the various sub-relationships may represent various different subdivisions within a customer, where each subdivision has distinct and specific customer needs that the software platform 300 may be designed to handle.
[0048] For example, a delivery person using, e.g., a wireless FIRST DOMAIN 310 and a mobile first hardware context 320 , may have a selected menu presentation such as bottom-up. The computational machine presentation therefore re-arranges a first navigational target to a presentation location that is nearer the origination point. In other words, the computational machine presentation therefore re-arranges a first navigational target to a presentation location that makes it a prominent navigational target. An associate of the delivery person using, e.g., a wide-area network (WAN) user SECOND DOMAIN 312 and a laptop (subsequent) hardware context 320 , may observe the menu presentation, but it may be identical to the presentation observable by the delivery person, e.g., bottom-up, or it may be a presentation that is different. Further, another associate of the delivery person using, e.g. an internet n th DOMAIN 314 and a desktop (subsequent) hardware context 3 , may observe the menu presentation, but it may be identical to the presentation observable by the delivery person, e.g., bottom-up, or it may be a presentation that is different. In other words, the computational machine presentation therefore re-arranges the first navigational target to a presentation location that is not nearer the origination point, rather, it may be re-arranged in a manner such as is depicted at 100 in FIG. 1 .
[0049] In an embodiment, the various sub-relationships may represent various different customer types that are not necessarily related as business entities, but where each subdivision has distinct and specific customer needs for that given customer type that the software platform 300 may be designed to handle.
[0050] The software platform 300 recognizes a user domain, a hardware context, a relationship, and a user interface 350 . The user interface 350 can vary even with a single user, as he may migrate among different hardware platforms, but may access the same application from the various different hardware platforms. Examples of various user interfaces (UIs) include a graphical UI 352 , an audio UI 354 , a tactile/motile UI 356 , or an other UI 358 . In an embodiment, any combination of the given UIs may be used to assist the user. In an embodiment, a user migrates between a first hardware platform and a second hardware platform, and retains the same UI presentation to the various illustrated embodiments depicted in FIG. 2
[0051] In an embodiment, a transformation of a bottom-up menu presentation for a given computational machine, such as the menu presentation 101 depicted in FIG. 1 , is carried out with a graphic UI 352 . In an embodiment, however, a visually impaired user may require a different UI. For example, a delivery person may be negotiating movement through vehicular and pedestrian traffic, and an audio UI 354 interface is more useful such that the delivery person may receive auditory feedback and need not divert his vision away from the traffic. The audio UI 354 , however, allows the delivery person to immediately access, e.g., the first navigational target 113 , and an audio signal informs the delivery person that the requested DAL has been accessed. In an embodiment with the delivery person, the delivery person may have tactile-sequential access to the UI 356 , but with a button push, an audio signal informs the delivery person that the requested DAL has been accessed by use of the audio UI 354 . Consequently, a combination graphical UI 352 , audio UI 354 , and tactile/motile UI 356 has been employed to assist the user.
[0052] In an embodiment, a user with visually impaired eyesight may use the audio UI 354 with neither graphical, not tactile/motile assistance. In this embodiment, the user makes a single audible command, which the audio UI 354 recognizes, and in an example embodiment, the audible command equivalent to “NAVIGATIONAL TARGET FIRST” but a simplified command such as “push”, which emulates single button push of a tactile/motile UI.
[0053] After the software platform 300 recognizes the domain, the hardware context, the relationship and sub-relationship if necessary, and the specific user interface, the software platform 300 accepts a query 360 . A query 360 may be a button push, an audible command, a screen position selection on a graphical UI, or an other query.
[0054] Thereafter, a rendering module 370 gives communication feedback through the hardware context 320 to the user. Accordingly, the computational machine presentation may be customized by re-arranging a first selectable target more likely to be selected first, to a presentation nearer the origination point. The software platform therefore allows a user to migrate between hardware contexts 320 , to migrate between domains, and even migrate between relationships, such that the user interface may be re-arranged to simplify or reduce the number and complexity of commands needed to efficiently access the given software.
[0055] FIG. 4 illustrates a time-dependent navigational tool for a radiant-energy menu computational machine presentation 400 according to an embodiment. This embodiment includes an origination point 410 . The origination point 410 is depicted with radiant-energy lines, as it represents an audio signal for example. The origination point 410 may also represent a visual presentation such as a single display at a given time. A timeline 408 represents a zeroth time for the origination point 410 , and several other times up to an n th time (t nth ) In an embodiment, a user invokes the origination point 410 by an audible command, and a first navigational target 413 is executed by an audio reply. When the user desires to access the DAL represented by the first navigational target 413 , the user may give a second audible command accordingly.
[0056] Should the user, however, choose a different navigational target, several other navigational targets may be broadcast to the user while he waits. FIG. 4 depicts other navigational targets such as a second navigational target 415 that represents a DAL, an intermediate navigational target 417 that represents a DAL, and a second to last navigational target 419 that represents a DAL as well as a last navigational target 421 that represents the last-accessed DAL. This embodiment may be used by the user, for example, where the user is visually impaired. Further according to an embodiment, the user may configure the radiant-energy menu presentation 400 in a given instance where he may be visually distracted by negotiating traffic. At another time, the user may configure a different menu presentation where he may not be visually distracted, but he may have migrated to a different hardware platform.
[0057] In an embodiment, the user may want an audio menu computational machine presentation 400 , but has tactile access to his hardware context 320 such as a hand-held computing machine. Where the user likely wants to navigate from the origination point 410 to the first navigational target 413 , a single command such as a single button push is first required, and the first navigational target 413 is presented. The user then may repeat a button push, or, he may give an audible command to access the DAL represented by the first navigational target 413 . Consequently, the user need not divert his attention from traffic, but with audible and haptic knowledge of the menu presentation but will navigate more easily from the origination point 410 to the first navigational target 413 by embracing the audio presentation or the haptic presentation.
[0058] FIG. 5 illustrates a hand-held platform 500 for accessing any of the menu presentation embodiments. The hand-held platform 500 can be a computational machine that includes a graphical UI 510 , an audio UI 512 , and a tactile/motile UI 514 . In an embodiment, a software platform such as the software platform 300 or a subset thereof, recognizes the hand-held platform 500 as an appropriate hardware context. The software platform may also recognize a domain, a relationship, and based upon a given likely user, a selected combination of UIs such as some of the UIs 350 depicted in FIG. 3 . The tactile/motile UI 514 is represented as four directional navigation buttons. It can be seen that a given user with the hand-held platform 500 , may access a given application by several combinations, including presenting the most likely to be accessed DAL first in time or closest to an origination point.
[0059] FIG. 6 illustrates a hand-held platform 600 for accessing any of the menu presentation embodiments. The hand-held platform 600 includes a graphical UI 610 , an audio UI 612 , and a tactile/motile UI 614 . In an embodiment, a software platform such as the software platform 300 or a subset thereof, recognizes the hand-held platform 600 as an appropriate hardware context. The software platform may also recognize a domain, a relationship, and based upon a given likely user, a selected combination of UIs such as some of the UIs 250 depicted in FIG. 3 . The tactile/motile UI 614 is represented as a toggle navigation button. It can be seen that a given user with the hand-held platform 600 , may access a given application by several combinations, including presenting the most likely to be accessed DAL first in time or closest to an origination point, or by displaying the same UI presentation because the user may have migrated to a different hardware platform.
[0060] In an embodiment, the software platform may be web-based accessible, and the specific UI configuration may be programmable into the hardware context, depending upon the specific user profile etc., and the tasks the user will be or is undertaking.
[0061] FIG. 7 illustrates a hand-held platform 700 for accessing any of the menu presentation embodiments. The hand-held platform 700 includes a graphical UI 710 , an audio UI 712 , and a tactile/motile UI 714 . In an embodiment, a software platform such as the software platform 300 or a subset thereof, recognizes the hand-held platform 700 as an appropriate hardware context. The software platform may also recognize a domain, a relationship, and based upon a given likely user, a selected combination of UIs such as some of the UIs 350 depicted in FIG. 3 . The tactile/motile UI 714 is represented as a single navigation button. With a single navigation button, and where the software platform assists the user, the hand-held platform 600 , may be used to access a given application by several combinations, including presenting the most likely to be accessed DAL first in time or closest to an origination point. Further with any of the input/output functionalities, a user may wrap around a presented menu if a given navigational target is missed.
[0062] Accordingly, a first hand-held platform may be a Pocket PC®, and a second hand-held platform may be a Blackberry®. In other words, a first computation computational machine and a second computational machine belong to a single user, and the user migrates from one to the other, but requires further computation on the second, as a continuing session from the first. Consequently, re-arranging the first selectable target is derived from instructions for the first computational machine. In the first computational machine, the first selectable target is originally presented nearer the origination point.
[0063] FIG. 8 is a diagram of a method 800 for presenting a navigational control record of a browsing session according to an example embodiment of the disclosure.
[0064] At 802 , the method includes recognizing a hardware context.
[0065] At 804 , the method includes recognizing a user interface.
[0066] At 806 , the method includes recognizing a query.
[0067] At 808 , the method includes at least one of recognizing a domain and a relationship.
[0068] At 810 , the method includes presenting a menu layout in a first presentation in a first hardware context.
[0069] At 820 , the method includes presenting the same menu layout in the first presentation in a second hardware context.
[0070] At 830 , the method includes rendering feedback through the second hardware context.
[0071] FIG. 9 is a block diagram of a computing machine 999 in the example form of a computer system 900 within which a set of instructions, for causing the machine 999 to perform any one or more of the methodologies discussed herein, may be executed. For example, computer instructions include generating a computational machine presentation using an origination point for a user and re-arranging a first selectable target more likely to be selected first, to a presentation nearer the origination point. In an embodiment, computer instructions recognize a user who has migrated between a first hardware platform and a second hardware platform, and the instructions are to preserve the UI configuration the user had in the first hardware platform.
[0072] In alternative embodiments, the machine operates as a standalone device or may be connected (e.g., networked) to other machines. In a networked deployment, the machine may operate in the capacity of a server or a client machine in server-client network environment, or as a peer machine in a peer-to-peer (or distributed) network environment. The machine may be a personal computer (PC), a tablet PC, a set-top box (STB), a Personal Digital Assistant (PDA), a cellular telephone, a web appliance, a network router, switch or bridge, or any machine capable of executing a set of instructions (sequential or otherwise) that specify actions to be taken by that machine. Further, while only a single machine is illustrated, the term “machine” shall also be taken to include any collection of machines that individually or jointly execute a set (or multiple sets) of instructions to perform any one or more of the methodologies discussed herein.
[0073] The example computer system 900 includes a processor 902 (e.g., a central processing unit (CPU), a graphics processing unit (GPU) or both), a main memory 904 and a static memory 906 that communicate with each other via a bus 908 . The computer system 900 may further include a video display unit 910 (e.g., a liquid crystal display (LCD) or a cathode ray tube (CRT)). The computer system 900 also includes an alphanumeric input device 912 (e.g., a keyboard), a user interface (UI) navigation device 914 (e.g., a mouse), a disk drive unit 916 , a signal generation device 918 (e.g., a speaker) and a network interface device 920 .
[0074] The disk drive unit 916 includes a machine-readable medium 922 on which is stored one or more sets of instructions and data structures (e.g., software 924 ) embodying or utilized by any one or more of the methodologies or functions described herein. The instructions 924 may also reside, completely or at least partially, within the main memory 904 and/or within the processor 902 during execution thereof by the computer system 900 , the main memory 904 and the processor 902 also constituting machine-readable media.
[0075] The instructions 924 may further be transmitted or received over a network 926 via the network interface device 920 utilizing any one of a number of well-known transfer protocols (e.g., hyper-text transfer protocol, HTTP). In various embodiments, the machine 999 is a wireless device and includes an antenna 930 that communicatively couples the machine 999 to the network 926 or other communication devices. Other devices may include other machines similar to the machine 999 , wherein the machine 999 and the other machines operate in an ad-hoc mode of communicator with one and other.
[0076] In various embodiments, the network 926 couples the machine 999 to a database 950 . In various embodiments, the database 950 includes data that may be displayed with assistance of the machine 999 by using the video display 910 .
[0077] While the machine-readable medium 922 is shown in an example embodiment to be a single medium, the term “machine-readable medium” should be taken to include a single medium or multiple media (e.g., a centralized or distributed database, and/or associated caches and servers) that store the one or more sets of instructions. The term “machine-readable medium” shall also be taken to include any medium that is capable of storing, encoding or carrying a set of instructions for execution by the machine and that cause the machine to perform any one or more of the methodologies of the disclosed embodiments, or that is capable of storing, encoding or carrying data structures utilized by or associated with such a set of instructions. The term “machine-readable medium” shall accordingly be taken to include, but not be limited to, solid-state memories, optical and magnetic media, and carrier wave signals. The disclosed embodiments can be implemented in digital electronic circuitry, or in computer hardware, firmware, software, or in combinations of them. The disclosed embodiments can be implemented as a computer program product, i.e., a computer program tangibly embodied in an information carrier, e.g., in a machine-readable storage device or in a propagated signal, for execution by, or to control the operation of, data processing apparatus, e.g., a programmable processor, a computer, or multiple computers. A computer program can be written in any form of programming language, including compiled or interpreted languages, and it can be deployed in any form, including as a stand-alone program or as a module, component, subroutine, or other unit suitable for use in a computing environment. A computer program can be deployed to be executed on one computer or on multiple computers at one site or distributed across multiple sites and interconnected by a communication network.
[0078] In various embodiments, the machine 999 includes a display generation module 940 . In various embodiments, the display generation module 940 is a software application. In various embodiments, the display generation module 940 includes hardware which may include a memory storage device 942 , which may include software stored on the memory storage device. In various embodiments, display generation module 940 is operable to generate commands to format data to be displayed on the video display 910 according to the various methods described herein.
[0079] The embodiments can be implemented in digital electronic circuitry, or in computer hardware, firmware, software, or in combinations of them. The disclosed embodiments can be implemented as a computer program product, for example, a computer program tangibly embodied in an information carrier, for example, in a machine-readable storage device or in a propagated signal, for execution by, or to control the operation of, data processing apparatus, for example, a programmable processor, a computer, or multiple computers. A computer program can be written in any form of programming language, including compiled or interpreted languages, and it can be deployed in any form, including as a stand-alone program or as a module, component, subroutine, or other unit suitable for use in a computing environment. A computer program can be deployed to be executed on one computer or on multiple computers at one site or distributed across multiple sites and interconnected by a communication network.
[0080] Method operations of any disclosed embodiments and their equivalents can be performed by one or more programmable processors executing a computer program to perform functions of the disclosed embodiments by operating on input data and generating output. Method operations can also be performed by, and apparatus of the disclosed embodiments can be implemented as, special purpose logic circuitry, for example, an FPGA (field programmable gate array) or an ASIC (application-specific integrated circuit).
[0081] Processors suitable for the execution of a computer program include, by way of example, both general and special purpose microprocessors, and any one or more processors of any kind of digital computer. Generally, a processor will receive instructions and data from a read-only memory or a random access memory or both. The essential elements of a computer are a processor for executing instructions and one or more memory devices for storing instructions and data. Generally, a computer will also include, or be operatively coupled to receive data from or transfer data to, or both, one or more mass storage devices for storing data, e.g., magnetic, magneto-optical disks, or optical disks. Information carriers suitable for embodying computer program instructions and data include all forms of non-volatile memory, including by way of example semiconductor memory devices, for example, EPROM, EEPROM, and flash memory devices; magnetic disks, for example, internal hard disks or removable disks; magneto-optical disks; and CD-ROM and DVD-ROM disks. The processor and the memory can be supplemented by, or incorporated in special purpose logic circuitry.
[0082] FIG. 10 is a diagram of an architecture 1000 according to various embodiments for generating a computational machine presentation. In various embodiments, the architecture 1000 includes a module 1020 . The module 1020 may be software, hardware, or may be a combination of software and hardware. In various embodiments, module 1020 may include software stored as instructions, for example the instructions 924 associated with the processor 902 in FIG. 9 . In various embodiments, the module 1020 may be the display generation module 940 as shown in FIG. 9 . In various embodiments, the module 1020 includes instructions that may be stored in more than one place within the architecture 1000 . In various embodiments, the module 1020 includes one or more of the following: hardware context recorder 1022 , user interface recorder 1023 , domain recorder 1024 , relationship recorder 1025 , and rendering type recorder 1026 . In various embodiments, the module 1020 is coupled to the data input interface 1010 . In various embodiments, the data input interface 1010 is operable to receive input data 1012 and to provide the module 1020 with the data, such as data derived from a user's navigation through an application.
[0083] In various embodiments, module 1020 is coupled to a display driver interface 1030 . In various embodiments, the display driver interface 1030 interfaces with the module 1020 to receive data provided by the module 1020 and provides an output 1032 to control a display. Various embodiments of apparatus, methods, and system have been described herein. Various embodiments include an apparatus comprising a display to provide a visual representation of a generation of a menu presentation relative to a given menu orientation.
[0084] Various embodiments include a system comprising a wireless device including an antenna to communicatively couple the wireless devices to one or more other devices, and the wireless device including a display and a display generation module couple to the display, the display generation module to generate commands to cause the display to provide a presentation generation of a menu presentation relative to a given menu orientation.
[0085] Various embodiments include a machine-readable medium embodying instructions that, when executed by a machine, cause the machine to display a generation of a menu presentation relative to a given menu orientation.
[0086] The embodiments can be implemented in digital electronic circuitry, or in computer hardware, firmware, software, or in combinations of them. The embodiments can be implemented as a computer program product, i.e., a computer program tangibly embodied in an information carrier, e.g., in a machine-readable storage device or in a propagated signal, for execution by, or to control the operation of, data processing apparatus, e.g., a programmable processor, a computer, or multiple computers. A computer program can be written in any form of programming language, including compiled or interpreted languages, and it can be deployed in any form, including as a stand-alone program or as a module, component, subroutine, or other unit suitable for use in a computing environment. A computer program can be deployed to be executed on one computer or on multiple computers at one site or distributed across multiple sites and interconnected by a communication network.
[0087] Method operations of the embodiments can be performed by one or more programmable processors executing a computer program to perform functions of the embodiments by operating on input data and generating output. Method operations can also be performed by, and apparatus of the embodiments can be implemented as, special purpose logic circuitry, e.g., an FPGA (field programmable gate array) or an ASIC (application-specific integrated circuit).
[0088] Processors suitable for the execution of a computer program include, by way of example, both general and special purpose microprocessors, and any one or more processors of any kind of digital computer. Generally, a processor will receive instructions and data from a read-only memory or a random access memory or both. The elements of a computer are a processor for executing instructions and one or more memory devices for storing instructions and data. Generally, a computer will also include, or be operatively coupled to receive data from or transfer data to, or both, one or more mass storage devices for storing data, e.g., magnetic, magneto-optical disks, or optical disks. Information carriers suitable for embodying computer program instructions and data include all forms of non-volatile memory, including by way of example semiconductor memory devices, e.g., EPROM, EEPROM, and flash memory devices; magnetic disks such as internal hard disks and removable disks; magneto-optical disks; and CD-ROM and DVD-ROM disks. The processor and the memory can be supplemented by, or incorporated in special purpose logic circuitry.
[0089] The embodiments can be implemented in a computing system that includes a back-end component, e.g., as a data server, or that includes a middleware component, e.g., an application server, or that includes a front-end component, e.g., a client computer having a graphical user interface or an Web browser through which a user can interact with an implementation of the embodiments, or any combination of such back-end, middleware, or front-end components. The components of the system can be interconnected by any form or medium of digital data communication, e.g., a communication network. Examples of communication networks include a local area network (“LAN”), a wide area network (“WAN”), and the Internet.
[0090] The computing system can include clients and servers. A client and server are generally remote from each other and typically interact through a communication network. The relationship of client and server arises by virtue of computer programs running on the respective computers and having a client-server relationship to each other.
[0091] Certain applications or processes are described herein as including a number of modules or mechanisms. A module or a mechanism may be a unit of distinct functionality that can provide information to, and receive information from, other modules. Accordingly, the described modules may be regarded as being communicatively coupled. Modules may also initiate communication with input or output devices, and can operate on a resource (e.g., a collection of information).
[0092] Although an embodiment have been described with reference to specific example embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the embodiments. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense. The accompanying drawings that form a part hereof, show by way of illustration, and not of limitation, specific embodiments in which the subject matter may be practiced. The embodiments illustrated are described in sufficient detail to enable those skilled in the art to practice the teachings disclosed herein. Other embodiments may be utilized and derived therefrom, such that structural and logical substitutions and changes may be made without departing from the scope of this disclosure. Embodiments from one or more drawings may be combined with embodiments as illustrated in one or more different drawings. This Detailed Description, therefore, is not to be taken in a limiting sense, and the scope of various embodiments is defined only by the appended claims, along with the full range of equivalents to which such claims are entitled.
[0093] While the foregoing disclosure shows a number of illustrative embodiments, it will be apparent to those skilled in the art that various changes and modifications can be made herein without departing from the scope of the embodiments as defined by the appended claims. Accordingly, the disclosed embodiment are representative of the subject matter which is broadly contemplated by the embodiments, and the scope of the embodiments fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the embodiments is accordingly to be limited by nothing other than the appended claims.
[0094] Moreover, ordinarily skilled artisans will appreciate that any illustrative logical blocks, modules, circuits, and process operations described herein may be implemented as electronic hardware, computer software, or combinations of both.
[0095] To clearly illustrate this interchangeability of hardware and software, various illustrative components, blocks, modules, circuits, and operations have been described above generally in terms of their functionality. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on the overall system. Skilled artisans may implement the described functionality in varying ways for each particular application, but such implementation decisions should not be interpreted as causing a departure from the scope of the embodiments.
[0096] The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the embodiments. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the embodiments. Thus, the embodiments are not intended to be limited to the embodiments shown herein but are to be accorded the widest scope consistent with the principles and novel features disclosed herein.
[0097] The abstract of the Disclosure is provided to comply with 37 C.F.R. §1.72(b), requiring an abstract that will allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.
[0098] In addition, in the foregoing Detailed Description, it can be seen that various features are grouped together in a single embodiment for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment. | Methods are disclosed for a computational machine presentation including an origination point for a user, re-arranging a first selectable target more likely to be selected first, to a presentation nearer the origination point. The presentation format persists for any given user across a variety of computational machines, thus minimizing the effort for a given user in terms of cross computational-machine transfer and in terms of an on the average shortened navigational distance for any of the computational machines. The persistent format is consistent for cross computational-machine transfer, and this consistency coincides with a systematic decrease in navigational distance. | 53,837 |
BACKGROUND OF THE INVENTION
The present invention relates to an automatic correction device in which the deviation of a vehicle from a running lane is automatically monitored and, when the deviation occurs, a brake pressure applied to at least one of the left and right wheel brakes is automatically increased, thereby automatically adjusting a distribution between pressures applied to left and right wheel brakes and returning the vehicle to the running lane. Hereafter, an adjustment of brake pressure distribution between left and right wheel brakes, i.e., a change of vehicle's travelling direction by a differential braking, is referred to as “brake steering”.
The above automatic correction of travelling direction is effective for temporarily securing the safety of the running vehicle, when a driver's watchfulness ahead of the running vehicle deteriorates, e.g., when the driver looks aside, falls asleep or is in a semi-comatose state before or after sleeping.
In “A Warning and Intervention System to Prevent Road-Departure Accidents” recited in Vehicle System Dynamics Supplement 25 (1996), pp 383-396, a vehicle travelling direction is automatically adjusted in the direction along which the vehicle moves by a feedback control in which a front view ahead of the vehicle is photographed by a television camera and a running lane is detected by image processing, vehicle behavior is inferred from information detected by another sensor mounted on the vehicle, and when an unintended deviation from the running lane occurs, the amount of deviation determines the amount of control with respect to wheel brake pressure distribution.
In “Correlation between Snaking of Vehicle and Awakening Degree” recited in Japan Automobile Technology Association's Scientific Lecture Preprints 941, pp. 25-28 published in May 1994, there is suggested a technique in which the front view ahead of the vehicle is photographed by a television camera, a white line partitioning a running lane is detected by image processing, and a lateral shift amount of the vehicle is computed, thereby detecting a snaking state of vehicle.
Detection of a running lane and detections of lane width, curve, a preceding vehicle or the like have been already suggested by the present applicant (for example, Japanese Patent Unexamined Publication No. 6-213660). Further, there has been suggested a technique in which a television camera for photographing a front view ahead of the vehicle is turned to follow a lane curve, thereby tracing a forward running lane (for example, Japanese Patent Unexamined Publication No. 9-96507). Furthermore, there has been suggested a distribution control technique for wheel brakes (for example, Japanese Patent Unexamined Publication No. 8-207737). By combining these techniques, the aforementioned automatic correction of travelling direction can be realized.
It is inferred that in the feedback control in which the amount of deviation determines the amount of control with respect to wheel brake pressure distribution, when the deviation amount is large, an increase in pressure for a wheel brake is high and when the former is small, the latter is low, so that the effect of correcting the deviation amount is high, but when the deviation amount is large a change in direction of the vehicle is great, so that depending on road conditions such an unstable behavior is liable to occur that an increase in wheel brake pressure becomes too high so the wheels are locked or that a change in direction of vehicle is so sharp the vehicle spins. Steering by a driver during running of a vehicle is performed generally in response to the car speed, a radius of curvature and the friction coefficient of the road surface. It is preferable that brake steering for the aforementioned automatic correction of travelling direction responds smoothly to a car speed, a radius of curve and a friction coefficient of road surface (these are combined and referred to as “running conditions”), and it is considered that brake steering not reflecting a driver's will should lay emphasis on a stable and gentle correction of direction rather than a rapid correction of the deviation amount. It is inferred that by introducing such parameters as a car speed, a radius of a curve, a yaw rate and the like to the aforementioned feedback control and revising the amount of operation in response to the above parameters, there is obtained an improvement in consistency and smoothness with respect to the running conditions. However, the characteristic that since the control amount is the deviation amount, if the deviation amount is large an increase in wheel brake pressure is high and a change in direction is large will be maintained because that characteristic is an object inherent in the aforementioned feedback control.
A driver in another vehicle is uneasy if a preceding vehicle, or a vehicle running in the opposite direction, rapidly changes its direction. In the event that another vehicle deviates from the lane, it is easier to cope with that vehicle when it returns slowly but stably and gradually to the lane judging from its running state than when it exhibits such a behavior that it returns rapidly to the lane.
It cannot be said that reliability of detecting a vehicle in the running lane is sufficient. Further, it is comparatively frequent that a deviation from the running lane or a change of the running lane is performed by a normal judgment of the driver in order to avoid another vehicle or an obstacle. Alternatively, the running lane is frequently changed as a result of the driver's intent. However, in these cases, a consistency between the driver's will and the brake steering is low. Therefore, it is preferable that a brake steering amount is made as small as possible in order to prevent a hindrance in driving the vehicle from occurring. To the contrary, when the driver's power of attention deteriorates (e.g., when the driver looks aside or falls asleep), it is preferable that the brake steering is strongly applied in the event that the vehicle deviates from the lane. However, at present it is difficult to realize these problems simultaneously by a feedback control.
Further, in a usual road in which there are many parked or stopped vehicles and many telephone or electric poles, the radius of curvature is small or across which many people and vehicles traverse, an error in detecting the running lane is liable to occur. Further, even if the running lane is accurately detected, a change of running lanes and a deviation from a lane is frequently performed. Under such situations, in view of the driver's recognition and intention, it is highly possible that the aforementioned automatic correction of travelling direction becomes a malfunction and becomes an erroneous interference to the driver. When a vehicle runs on a large road, e.g., a freeway (road exclusively for vehicles), on which it can keep a comparatively high speed with little possibility of sharp steering for avoiding another vehicle or the like and whose smallest radius of curve is comparatively large, driving at a substantially constant speed with little steering continues for a long time. For example, there is also a situation where the driver selects an automatic cruising which conducts an intra-vehicle control or a fixed speed control. Under such running conditions, since the incentive to stay awake is small, it is liable to make the driver sleepy. The aforementioned automatic correction of travelling direction is effective for supplementing the driver's carelessness under such running conditions.
SUMMARY OF THE INVENTION
A first object of the present invention is to provide brake steering which is high in consistency with respect to the running conditions and is high in stability of direction correction. A second object of the present invention is to provide brake steering which jogs an uplift of the driver's power of attention.
Further, a third object of the present invention is to increase the reliability of the aforementioned automatic control of travelling direction, which is appreciated by the driver. A fourth object of the same is to suppress an erroneous interference with the driver. A fifth object of the same is to increase the consistency and smoothness of brake steering with respect to the running conditions of vehicle.
A first mode of the present invention for achieving the above first and second objects relates to the following (1).
(1) A travelling direction correcting apparatus comprising::
a shift detection device ( 140 , 160 ) for detecting a shift amount of a vehicle (CAR) running on a road with respect to the road;
a wheel brake pressure control device ( 10 , 30 ) for increasing the pressure in wheel brakes ( 51 - 54 ) of the vehicle and controlling wheel brake pressure distribution; and
cruise control means ( 100 ) for commanding a wheel brake pressure distribution control to the wheel brake pressure control device ( 10 , 30 ), where in the wheel brake pressure distribution control the following processes are implemented:
(1) at least one of a yaw rate (Y), a lateral speed and a lateral acceleration (GY) provides an index,
(2) a value (yawS) of the index, which appears in the vehicle when its running direction is changed toward a direction along which the shift amount decreases, is added to a value (v/R) of the index, which appears when the vehicle runs along a curved road, and a summed amount (v/R+yawS) is made an object value and
(3) the value (Y) of the index, which appears in the vehicle, is coincided with the object value (v/R+yawS).
The above wheel brake pressure distribution control, i.e., brake steering is not one in which the shift amount (deviation amount) is made a control amount, but the feedback control in which the yaw rate (Y), the lateral speed and/or the lateral acceleration (GY) are/is made a control amount. In the embodiment mentioned later by referring to the drawings, since the yaw rate (Y) is made a control amount, it is explained on the basis of this embodiment. The brake steering is a feedback control in which the yaw rate is made a control amount and the wheel brake pressure is made an operation amount. Since the yaw rate (Y) is a value responding to vehicle's running conditions, the summed value (v/R+yawS) obtained by adding the yaw rate (yawS) for brake steer to the yaw rate (Y≈v/R) appearing when the brake steering is not acting is made an object value. If the wheel brake pressure distribution is controlled in such a manner that an actual yaw rate (Y: detection amount) coincides with the object value (v/R+yawS), a brake steering generating the yaw rate (yawS) by an amount of basis acts on the vehicle.
A steering amount due to this steering does not depend on the shift amount (deviation amount), but is one which additionally generates the yaw rate b an amount of bias irrespective of what the vehicle speed (v) and the road curve radius (R) are. In other words, the vehicle is given a desired change of direction without being influenced by its running condition. In the embodiment mentioned later, the yaw rate by an amount of bias is expressed as yawS=±2°/sec and is a low value. This yaw rate value is one which falls within a range defined by a lower limit value necessary for applying an effective pressure to the wheel brake and upper limit value below which it can be deemed that the vehicle's direction change is moderate and, moreover, it a value which is slightly lower than an intermediate value between the above lower and upper limit values. By this, the vehicle's direction change becomes one which is stable and moderate.
(2) The travelling direction correcting apparatus further comprises annunciator means ( 110 , 120 ), the cruise control means ( 100 ) emits a primary alarm at said annunciator means ( 110 , 120 ) when the shift amount is more than a first set value (0 m), emits a secondary alarm at said annunciator means when the shift amount is more than a second set value (1 m) which exceeds the first set value and commands the wheel brake pressure distribution control to the wheel brake pressure control device ( 10 , 30 ).
According to this, the first alarm is emitted when the vehicle's shift (deviation amount) from the lane is about to become large. When the vehicle's shift (deviation amount) is large, the secondary alarm (i.e., brake steering implementation annunciation) is emitted and brake steering in the above (1) is automatically implemented.
(3) The above index is a yaw rate (Y).
(4) A travelling direction correcting apparatus comprising:
a shift detection device ( 140 , 160 ) for detecting a shift amount of a vehicle (CAR) running on a road with respect to the road;
a wheel brake pressure control device ( 10 , 30 ) for increasing the pressure in the wheel brakes ( 5154 ) of the vehicle and controlling a wheel brake pressure distribution; and
annunciator means ( 110 , 120 ); and
cruise control means ( 100 ) which emits a primary alarm at the annunciator ( 110 , 120 ) when the shift amount is more than a first set value (0 m), emits a secondary alarm when the shift amount is more than a second set value (1 m) which exceeds the first set value and commands a wheel brake pressure distribution control for decreasing the shift amount and fluctuating the shift amount in timed series to the wheel brake pressure control device ( 10 , 30 ).
According to this, the first alarm is emitted when the vehicle's shift (deviation amount) from the lane is about to become large. When the vehicle's shift (deviation amount) is large, the secondary alarm (i.e., brake steering implementation annunciation) is emitted and the brake steering is automatically implemented. Since this brake steering decreases the lane deviation and fluctuates the shift amount in time series, the vehicle fluctuates leftward/rightward with respect to the direction along which the vehicle is traveling which is considered the center, thereby exerting a yaw rate vibration (lateral acceleration vibration) to the driver. This is different from the usual rate during steady running, so that the driver's power of attention is heightened. It is an advantage that the concerned vehicle attracts another driver's attention.
(5) The travelling direction correcting apparatus further comprises means (YA) for detecting a yaw rate of said vehicle, wherein the wheel brake pressure control device ( 10 , 30 ) performs a wheel brake pressure distribution in which a vibration yaw rate [yawS (1+sin ωτ)], which is formed by superimposing a fluctuation yaw rate (sin ωτ) increasing/decreasing in time series to a yaw rate (yawS) for correcting a shift in the same direction as a direction of a yaw rate appearing in the vehicle when its running direction is changed toward a direction along which the shift amount decreases, is computed and a yaw rate (Y) detected by the yaw rate detecting means (YA) is changed by an amount of the vibration yaw rate.
(6) The wheel brake pressure control device ( 10 , 30 ) performs a wheel brake pressure distribution in which a value, which is obtained by adding the vibration yaw rate [yawS (1+sin ωτ)] to a yaw rate (v/R) appearing in the vehicle correspondingly to a vehicle speed (v) and a curve radius (R) of the road, is made an object yaw rate [yawO=v/R+yawS (1+sin ωτ) ] and a yaw rate (Y) detected by the yaw rate detecting means (YA) is coincided with the object yaw rate (yawO).
(7) The cruise means ( 100 ) tests yes/no of a travelling direction correction and, in the event that it is yes, emits a primary alarm at the annunciator means ( 110 , 120 ) when the shift amount (deviation amount) is more than a first set value (0 m), emits a secondary alarm at the annunciator means ( 110 , 120 ) when the shift amount is more than a second set value (1 m) which exceeds the first set value and commands a wheel brake pressure distribution control for decreasing the shift amount (deviation amount) to the wheel brake pressure control device ( 10 , 30 ).
According to this, “yes” is judged in accordance with a logic testing yes/no of the travelling direction correction and moreover the first alarm (i.e., preliminary alarm is emitted when the vehicle's shift (deviation amount) from the lane is going to become large. When y is judged in accordance with a logic testing yes/no of the travelling direction change and moreover the vehicle's shift (deviation amount) is large, the second alarm (i.e., brake steering implementation annunciation) is emitted and the brake steering is implemented. If the vehicle is returned by the driver to lane center in response to the primary alarm, the primary alarm is extinguished and the brake steering does not start.
If a result of the travelling direction yes/no testing is “no”, the primary alarm is not emitted, and the reliability of the primary alarm is high and so the effect of arousing the driver's attention is high. Since the second alarm exists when the brake steering is working due to an automatic intervention of the cruise control means ( 100 ), the driver can recognize the fact that the brake steering is working. The reliability with respect to the travelling direction automatic correction appreciated by the driver becomes high. By heightening the reliability of the travelling direction correction yes/no testing, erroneous interference with the driver becomes shall and moreover a consistency and a smoothness of the brake steering with respect to the vehicle's running conditions becomes high.
For example, when the driver is dozing off and is not sufficiently awakened by the primary and secondary alarms, the vehicle fluctuates leftward/rightward with respect to the direction along which the vehicle is travelling which is considered the center, thereby exerting a yaw rate vibration (lateral acceleration vibration) to the driver. This is different from the yaw rate during a steady running and stimulates the driver, so that the effect of awakening a driver is high.
(8) The cruise control means ( 100 ) commands a stoppage of the wheel brake pressure distribution control to the wheel brake pressure control device ( 10 , 30 ) in response to the operation of equipment on the vehicle, which is performed by a driver. According to this, if the driver operates the equipment on the vehicle by being stimulated by the primary alarm, the secondary alarm or the fluctuating brake steering, the travelling direction correction is stopped. Since the primary alarm and the secondary alarm arouse the driver's attention and the travelling direction correction is stopped in response to the driver's equipment operation, interference to driving by the driver is small and the reliability appreciated by the driver becomes high.
A second mode of the present invention for achieving the aforementioned third and fourth objects relates to the following (1).
(1) A traveling direction correcting apparatus comprising:
a shift detection device ( 160 , 140 ) for detecting a shift amount (deviation amount) of a vehicle (MCR) running on a road with respect to said road;
a wheel brake pressure control device ( 10 , 30 ) for increasing wheel brake pressure ( 51 - 54 ) of said vehicle and controlling wheel brake pressure distribution;
annunciator means ( 110 , 120 ); and
cruise control means ( 100 ) for commanding a wheel brake pressure distribution control to the wheel brake pressure control device ( 10 , 30 ), wherein in the wheel brake pressure distribution control the following processes are implemented:
(1) yes/no of a travelling direction correction is tested and
(2) in the event that it is yes, when the shift amount (deviation amount) is more than a first set value (0 m) a primary alarm is emitted at the annunciator means ( 100 , 120 ) and when said shift amount is more than a second set value (1 m) which exceeds the first set value a secondary alarm is emitted at the annunciator means ( 100 , 120 ), thereby decreasing the shift amount (deviation amount). “Yes” is judged in accordance with a logic testing yes/no of the travelling direction correction and moreover the first alarm i.e., preliminary alarm is emitted when the vehicle's shift (deviation amount) from the lane is going to become large. When Y is judged in accordance with a logic testing yes/no of the travelling direction change and moreover the vehicle's shift (deviation amount) is large, the second alarm i.e., brake steering implementation annunciation) is emitted and brake steering is implemented. If the vehicle is returned by the driver to lane center in response to the primary alarm, the primary alarm is extinguished and brake steering does not start.
If a result of the travelling direction yes/no testing is “no”, the primary alarm is not emitted, and a reliability of the primary alarm is high and so the effect of arousing the driver's attention is high. Since the second alarm exists when the brake steering is working owing to an automatic intervention of the cruise control means ( 100 ), the driver can recognize the fact that the brake steering is working. The reliability with respect to the travelling direction automatic correction appreciated by the driver becomes high. By heightening the reliability of the travelling direction correction yes/no testing, an erroneous interference with the driver becomes small and moreover the consistency and the smoothness of the brake steering with respect to the vehicle's running conditions become high.
(2) The cruise control means ( 100 ) judges that the travelling direction correction is yes when the vehicle speed automatic control (intra-vehicle control/fixed speed run) is instructed by a driver.
In the embodiment mentioned later, if a fixed speed run is instructed by a switch operation of a driver, the cruise control means ( 100 ) writes a vehicle speed at that time in a object vehicle speed register. Thereafter, until a fixed speed run release condition is brought into existence, a throttle valve of engine mounted on the vehicle is subjected to an open/close control in such a manner that the vehicle speed coincides with the vehicle speed (object vehicle speed) of the object vehicle speed register. If an intra-vehicle control is instructed by a switch operation of the driver, until an intra-vehicle release condition is brought into existence, the throttle valve is subjected to an open/close control in such a manner that the distance from a preceding vehicle detected by a shift detection device ( 160 , 140 ) becomes an intra-vehicle distance suitable for the vehicle speed.
These vehicle speed automatic controls are suitable for a run on a road, such as a freeway, on which the vehicle can keep a comparatively high speed and the possibility of sharp steering for avoiding, for example, another vehicle is low and whose minimum curve radius is comparatively large. Start conditions and release conditions of the above automatic controls are highly similar to those of the brake steering. It is inferred from the fact that the above automatic controls are being implemented, correction (brake steering) is high and moreover safety in its implementation is high as well. Therefore, according to the present implementation mode, it may be said that the reliability of the travelling direction correction yes/no testing is high, an erroneous interference with a driver's driving is low and moreover the brake steering consistency and smoothness with respect to the vehicle running condition is high.
(3) The cruise control means ( 100 ) judges that the travelling direction correction is yes when the vehicle running speed (V) continues for a time longer than a set time (five minutes) at a speed higher than a set value ( 60 Km/H). From this, it is inferred that the running state is stable and, moreover, a further stable run continues. In this case, since there is a possibility that a driver becomes careless, it is inferred that the necessity of the travelling direction correction (brake steering) is high and moreover safety in its implementation is high as well. Therefore, according to the present implementation mode, it may be said that reliability of the travelling direction correction yes/no testing is high, an erroneous interference with a driver's driving is low and moreover the brake steering consistency and smoothness with respect to the vehicle running is high.
(4) The cruise control means 100 judges that the travelling direction correction is yes when the running road information on the basis of GPS position measurement and map data are (freeway/road exclusively for vehicles) corresponding to the vehicle speed automatic control yes. In the embodiment mentioned later, the GPS information processing ECU ( 190 ) computes a present position of vehicle on the basis of information received from GPS satellite, and map information possessed by the ECU ( 190 ) is referenced with the present position and a relative position between the road on which the vehicle is running, the present position on the map and the index is computed and outputted. In the map data, there are additional data representing the road's standards and regulations. The cruise control means ( 100 ) obtains such additional information from the GPS information processing ECU ( 190 ), and judges whether the road, on which the vehicle is running at present, is one on which it can run stably at a high speed for a long time. If it is judged so, it is judged that the travelling direction correction is yes.
Precision and stability of the GPS position measurement and those of the map data, both being available nowadays, are high. Further, in case of a freeway, the vehicle's adaptability to the vehicle speed automatic control is high and so there is such a possibility that the driver will become careless. Accordingly, it is inferred that the necessity of travelling direction correction (brake steering) is high and safety in implementing it is high as well. Therefore, according to the present implementation mode, it may be said that reliability of the travelling direction correction yes/no testing is high an erroneous interference with a driver's driving is low and moreover the brake steering consistency and smoothness with respect to the vehicle running is high.
(5) The cruise control means ( 100 ) judges that the travelling direction correction is yes when the instruction that the travelling direction correction is yes has been instructed (deviation alarm main SW is ON) by a driver. Since the travelling direction correction is made yes by the driver's will, and since it is possible for the driver to release that instruction to thereby make the travelling direction correction no, adaptability to the driver's will is high.
(6) The cruise control means ( 100 ) judges that the travelling direction control is yes when a curve radius (R) of a running lane detected by the deviation detection device ( 160 , 140 ) is larger than a set value (900 m) and a running time continues for a time longer than a set time (five minutes). From this, it is inferred that the running state is stable and, moreover, a further stable running continues. In this case, since there is a possibility that a driver becomes careless, it is inferred that the necessity of the travelling direction correction (brake steering) is high and moreover safety in its implementation is high as well. Therefore, according to the present implementation mode, it may be said that reliability of the travelling direction correction yes/no testing is high, an erroneous interference with a driver's driving is low and moreover, the brake steering consistency and smoothness with respect to the vehicle running is high.
A travelling direction correcting apparatus comprising:
a shift detection device ( 160 , 140 ) for detecting a shift amount deviation amount of a vehicle (MCR) running on a road with respect to the road;
a wheel brake pressure control device ( 10 , 30 ) for pressure-increasing wheel brakes ( 51 - 54 ) of the vehicle and controlling a wheel brake pressure distribution;
annunciator ( 110 , 120 ) means; and
cruise control means ( 100 ) which emits a primary alarm at the annunciator means ( 110 , 120 ) when the shift amount (deviation amount) is more than a first set value (0 m), emits a secondary alarm at the annunciator means ( 110 , 120 ) when the shift amount is more than a second set value (1 m) which exceeds the first set value, commands a wheel brake pressure distribution control for decreasing the shift amount to the wheel brake pressure control device ( 10 , 30 ) and commands a stoppage of the wheel brake pressure distribution control to the wheel brake pressure control device ( 10 , 30 ) in response to an operation of equipment on the vehicle, which is performed by a driver.
According to this, the first alarm is emitted when the vehicle's shift (deviation amount) from the lane is going to become large. When the vehicle's shift (deviation amount) is large, the secondary alarm (i.e., brake steering implementation annunciation) is emitted and the brake steering is automatically implemented. When the primary alarm or the secondary alarm is emitted, if a driver operates the equipment mounted on the vehicle, the travelling direction correction is stopped and the above alarm stops. Since the primary alarm and the secondary alarm arouse the driver's attention and the travelling direction correction is stopped in response to the driver's equipment operation, interference with the driving by the driver is low and a reliability appreciated by the driver becomes high.
An operation effected by the driver to actuate the equipment on the vehicle is a turning the steering wheel mounted on the vehicle. When the deviation from the lane occurs, the member to be operated by the driver is the steering wheel. When a steering contradictory to the turning of steering wheel, an erroneous interference with the driver's will occurs by any chance, the driver stops the travelling direction change by the brake steering and operates the steering wheel in order to change the direction to an intended direction. In the present implementation mode, since the travelling direction correction is stopped in response to the driver's action and the reliability appreciated by the driver becomes high.
(9) An operation effected by the driver to actuate the equipment on the vehicle is a turning of a steering wheel whose torque exceeds a set value (2 Nm). When the brake steering is contradictory to the driver's will, the driver stops the travelling direction change by the brake steering and operates the steering wheel in order to change the direction to an intended direction. In this case, the operation of steering wheel intends a direction change which is reverse in direction to the travelling direction change by the brake steering, so that rotational torque of the steering wheel is high. In the present implementation mode, since the travelling direction correction is stopped in response to this high torque, the brake steering is automatically stopped when the brake steering becomes an erroneous interference with the driving of the driver. Therefore, reliability appreciated by the driver becomes high.
(10) An operation effected by the driver to actuate the equipment on the vehicle is a turn signal operation. If the driver operates a turn signal to change the lane, since the travelling direction correction is stopped, the brake steering automatically stops when it becomes an erroneous interference with the lane change effected by the driver.
(11) An operation effected by the driver to actuate the equipment on the vehicle is an application of the brake pedal. Usually, the driver applies the brake pedal when avoiding nearness to another vehicle. Further, the brake pedal is applied when the vehicle reaches a state that the vehicle exhibits non-intended behavior. In that case, the brake steering is automatically stopped and it automatically stops when there is a possibility that it becomes an erroneous interference to the driving of a driver.
(12) A travelling direction correcting apparatus comprising:
a shift detection device ( 160 , 140 ) for detecting a shift amount (deviation amount) of a vehicle (MCR) running on a road with respect to the road;
a wheel brake pressure control device ( 10 , 30 ) for pressure-increasing wheel brakes ( 51 - 54 ) of the vehicle and controlling a wheel brake pressure distribution;
Annunciator means ( 110 , 120 ); and
cruise control means ( 100 ) which emits a primary alarm at the annunciator means ( 110 , 120 ) when the shift amount (deviation amount) is more than a first set value (0 m), emits a secondary alarm at the annunciator means ( 110 , 120 ) when the shift amount (deviation amount) is more than a second set value (1 m), which exceeds the first set value, and commands a wheel brake pressure distribution control for decreasing said deviation amount to the wheel brake pressure control device ( 10 , 30 ), and; if the shift amount decreases to a value less than a third set value (10 m) which is less than the second value, commands a stoppage of said wheel brake pressure distribution control to said wheel brake pressure control device ( 10 , 30 ), thereby stopping the alarm or changing said alarm to another annunciation.
According to this, the first alarm is emitted when the vehicle's shift (deviation amount) from the lane is going to become large. When the vehicle's shift (deviation amount) is large, the secondary alarm (i.e., brake steering implementation annunciation) is emitted and the brake steering is automatically implemented. This brake steering stops when the shift (deviation amount) has decreased to a third set value (0 m) less than the second set value which is a starting threshold of the brake steering. That is, with respect to start/finish of the brake steering, there are hysteresis characteristics to the shift (deviation amount).
By this, there is no possibility that the brake steering is repeated in comparatively short cycle in such a manner that, e.g., if the shift (deviation amount) becomes above the second set value, the brake steering starts→by this brake steering if the shift (deviation amount) becomes below the second set value, the brake steering stops→by a small displacement if the shift (deviation amount) becomes the second set value, the brake steering starts. Therefore, reliability of automatic correction of travelling direction, which is appreciated by the driver, is improved and the brake steering consistency and smoothness with respect to the vehicle running conditions is high.
Other objects and features of the present invention will become clear by the following description of embodiments making reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing one embodiment of the present invention;
FIG. 2 is a side view of a driver's seat in a vehicle equipped with a television camera 160 shown in FIG. 1;
FIG. 3 is a flowchart of the processing function of a cruise control ECU 100 shown in FIG. 1;
FIG. 4 is a flowchart showing a portion of the “lane deviation control processing” 6 shown in FIG. 3;
FIG. 5 is a flowchart showing another portion of the “lane deviation control processing” 6 shown in FIG. 3;
FIG. 6 is a flowchart showing remaining portions of the “lane deviation control processing” 6 shown in FIG. 3;
FIG. 7 is a flowchart showing the processing function of the brake control ECU 10 shown in FIG. 1;
FIG. 8 is a flowchart showing one mode of the “direction correction processing” 86 shown in FIG. 7;
FIG. 9 is a flowchart showing another mode of the “direction correction processing” 86 shown in FIG. 7; and
FIG. 10 is a flowchart showing a modified example of the “lane deviation control processing” 6 shown in FIG. 4 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, there is shown one embodiment of the present invention, which is mounted on a vehicle. A GPS position measurement device comprises a receiving antenna 201 , a GPS receiver 202 , a GPS demodulator 203 , a display unit 205 , a piezoelectric vibration gyro 206 , an altitude sensor 207 , a GPS information processing ECU (electronic control unit) 190 and an operation board 204 . An electric wave of 1.5742 GHz transmitted from each satellite of the GPS is received by the GPS receiver 202 via the receiving antenna 201 , and information, i.e., information on a function representing the satellite's orbit, a time and the like, are demodulated by the demodulator 203 and inputted to the GPS information processing ECU 190 . The GPS information processing ECU 190 is a computer system which comprises an armanac data memory, a map memory and a memory for date buffer as well as an input/output interface (electric and/or electronic circuit) and which has a microprocessor as its main component. The CPU generates information (latitude, longitude, altitude) representing a position of the concerned vehicle on the basis of information transmitted from the GPS satellite, and on the basis this position information one page (one screen) containing the above position is read from the map memory and this is displayed on the display unit 205 , thereby displaying a present position index to the present position on display. Basic constituent such as the receiving antenna 201 , the GPS receiver 202 , the GPS demodulator 203 and the display unit 205 as well as basic operations of the GPS information processing ECU 190 are similar to respective constituent elements of a known apparatus already on sale.
Analog signals outputted by the piezoelectric vibration gyro 206 and the altitude sensor 207 are respectively inputted to the GPS information processing ECU 190 , and in the GPS information processing ECU 190 the inputted information is converted to digital data via an A/D converter and read thereby. Information outputted from the GPS demodulator 203 and information for controlling the GPS demodulator 203 are inputted to the CPU or outputted from the CPU via I/O port of the GPS information processing ECU 190 .
The GPS information processing ECU 190 computes three-dimensional coordinates Ux, Uy, Uz for the position of the concerned vehicle by a “3-satellite position measurement operation” or a “4-satellite position measurement operation”.
In a “3-satellite position measurement operation”, three sets of data received from three satellites are substituted, respectively as parameters, to ternary simultaneous equations having been determined beforehand, and a latitude and a longitude at a reception point, which are unknowns, and a clock error at the reception side are obtained by solving these simultaneous equations. Further, in a “4-satellite position measurement operation”, four sets of data received from four satellites are substituted, respectively as parameters, to quadruple simultaneous equations having been determined beforehand, and a latitude and a longitude at a reception point, which are unknowns, and a clock error at the reception side are obtained by solving these simultaneous equations. Furthermore, since the clock error at the reception side is obtained by either of the above position measurement operations, a built-in clock is calibrated on the basis of this error information.
On the basis of position information obtained by the GPS position measurement, a map data of one page (one screen) containing that position is read from a map memory, and this is displayed on the display unit 205 , thereby displaying the present position index for the present position on display. Then, the GPS information processing ECU 190 reads additional information, such as “road information, representing standards and regulations for a road on which the present position is located, and information representing this is displayed on the display unit 205 and data representing that the GPS data is effective and the road conditions are written in an output data storage area, which is addressed to a cruise control ECU 100 with a memory for DMA transfer within the GPS information processing ECU 190 . When the GPS position measurement is unsuccessful, “invalid” is newly written in the above area, and when the GPS position measurement is successful, the fact that the GPS data is valid and the road information are newly written in the above area every time the road information is read from the map memory. The cruise control ECU 100 (its CPU) can read the data in the above area by using the DMA transfer when needed.
A television camera 160 supported by a rotary mechanism 170 is connected to an image processing ECU 140 . The rotary mechanism 170 contains therein an electric motor for rotary drive and reduction gears, and the camera 160 is fixed to an output rotary shaft of the reduction gears. The rotary mechanism 170 is supported by a frame, and as shown in FIG. 2 it is disposed in the vicinity of a central, upper portion of a front window within a vehicle MCR. The television camera 160 photographs a scene in front of the vehicle and outputs analog signals of 512×512 pixels per one frame.
In case of a curved road, there is a strong possibility that the camera photographs in a direction deviated from the road. Accordingly, in the present embodiment, the image processing ECU 140 performs the detection of the running lane in front of the vehicle, a computation of a curve radius R of the lane, a computation of lane width, a computation of lane deviation amount (shift amount) of the concerned vehicle MCR, a detection of a preceding vehicle and a computation of the distance from the preceding vehicle, and when a preceding vehicle is not detected, the camera 160 is rotated in such a manner that the center of the camera's field of view is coincident with the lane center. When a preceding vehicle exists in the camera's field of view, the camera is rotated in such a manner that the preceding vehicle is placed in the center of the field of view.
The camera 160 and constitution and function of the image processing ECU 140 are similar to those suggested in the aforementioned Japanese Patent Unexamined Publication No. 6-213660. Further, constitution and function relating to rotating the camera 160 are similar to those suggested in the aforementioned Japanese Patent Unexamined Publication No. 9-96507.
The image processing ECU 140 's constitution and function and the camera 160 and constitution and function of the camera's rotating mechanism are similar to those suggested in the aforementioned Japanese Patent Unexamined Publication No. 9-96507. The camera's photographed image is image-processed to detect a left white line (L: detection line) and a right white line (R: detection line) which partition a running lane, and a center line (Y) with respect to the vehicle width is defined and, thereafter, the lateral distance XL between L and Y and the lateral distance XR between Y and R are computed. This processing technique is disclosed in the aforementioned Japanese Patent Unexamined Publication No. 6-213660. In the present embodiment, the image processing ECU 140 further computes the vehicle's left-side deviation amount [(Vw/w)−XL] with respect to the lane and the vehicle's right-side deviation amount [Vw/2−XR]. Vw is a vehicle width (lateral width). As between the left-side and right-side deviation amounts, the larger value is considered the lane deviation.
Information of this lane deviation and whether the lane deviation exists left-side or right-side and information representing lane detection data, a lane curve radius R, a preceding vehicle detection -yes/no and a preceding vehicle distance (when a preceding vehicle is detected) are written together in a storage area, which is addressed to the cruise control ECU 100 and a memory for DMA transfer within the image processing ECU 140 . When the detection of a running lane is unsuccessful, “invalid” is written or updated in the storage area. When the detection of a running lane is successful, every time the computation or detection of the curve radius R, the vehicle deviation amount, the presence of a preceding vehicle -yes/no and the preceding vehicle distance is performed, this information is written or updated in the storage area. The cruise control ECU 100 , by means of its CPU, can read data in the storage area by using DMA transfer when desired.
A wheel brake fluid circuit 30 contains a brake pedal, a vacuum booster and a brake master cylinder, and further contains a first brake pressure source which generates a brake pressure corresponding to the driver's brake pedal applying force, a second brake pressure source which generates a second pressure by a pump that is driven by a motor, and an electromagnetic valve for wheel brake pressure operation, which selectively supplies one of the first pressure and the second pressure to wheel brakes 51 - 54 as disclosed in the aforementioned Japanese Patent Unexamined Publication No. 8-207737.
A brake control ECU 10 estimates a vehicle drift amount and a vehicle spin amount, and on the basis of these estimated values it is judged whether a vehicle turning is in an excessively insufficient area and if it is in the excessively insufficient area, a wheel brake whose wheel brake pressure should be increased is determined, and the second pressure is supplied to the determined wheel via the wheel brake fluid circuit 30 . That is, a wheel brake pressure distribution control is performed. As this distribution control, there are “B-STR control” for all wheels and “2-BDC control” for two rear wheels. As to “B-STR control” for all wheels, there are additional controls, i.e., “B-STR-OS” control for suppressing an over-steering and “B-STR-US” control for suppressing an understeering. The brake control ECU 10 further implements “ABS control” (antiskid control) and “TRC control” (traction control) as well.
A rotating speed of each of wheels 51 - 54 , i.e., wheels of front-right, front-left, rear-right and rear-light, is detected respectively by wheel speed sensors 41 - 44 , and an electric signal (wheel speed signal) representing each wheel speed is given to the brake control ECU 10 . A brake SW 45 which is closed when the brake pedal is applied gives an electric signal representing its open (pedal is not applied: OFF)/close (pedal is applied: ON) condition to the brake control ECU 10 .
A yaw rate of the vehicle is detected by a yaw rate sensor A, and an electric signal representing the yaw rate (actual yaw rate) γ is generated and given to the brake control ECU 10 . A turning angle of steering wheel is detected by a front wheel steerage angle sensor θF, and an electric signal representing a front wheel steerage angle θf is given to the brake control ECU 10 . A steerage angle of rear wheel is detected by a rear wheel steerage angle sensor OR, and an electric signal representing a rear wheel steerage angle θr is given to the brake control ECU 10 . A steering torque Tr exerted on a front wheel steering mechanism is detected by a torque sensor ST, and an electric signal representing the steering torque Tr is given to the brake control ECU 10 . A forward/rearward acceleration gx of car body is detected by an acceleration sensor (GX sensor), and an electric signal representing the forward/rearward acceleration is given to the brake control ECU 10 . A lateral acceleration gy of car body is detected by an acceleration sensor (GY sensor), and an electric signal representing the lateral acceleration is given to the brake control ECU 10 .
The brake control ECU 10 reads information of the above sensors, switches and the like and computes data used in ABS control, 2-BDC control (braking force distribution control for two rear wheels), TRC control and B-STR control (braking force distribution control for four wheels), and on the basis of these it is judged whether a start, a continuation or a finish of the above, various controls is necessary or not. And “ABS control”, “2-BDC control”, “TRC control” and/or “B-STR control” are performed depending on the judgment, thereby generating a wheel brake pressure operation output (open/close and timing of the electromagnetic valve) for these various controls, and the wheel brake fluid circuit 30 is operated by adjusting the wheel brake pressure operation output on the basis of a priority order of the above, various controls. That is, the electromagnetic valve is operated. When a steering by the braking force distribution control is insufficient, the brake control ECU 10 gives a steering instruction to 4-WS control ECU 60 and further gives a command for closing a sub-throttle to a throttle control ECU 80 , and thus a sub-throttle of engine is closed by a throttle driver 90 , thereby decreasing an output of engine. Contents of these controls are ones suggested in the aforementioned Japanese Patent Unexamined Publication No. 8-207737.
In the present embodiment, in the brake control ECU 10 , the cruise control ECU 100 revives the detected signals and data of the sensors, the switches, etc. and the information representing the data computed by the ECU 10 and the determined control mode. In addition, there is a memory for DMA transfer and for receiving a brake steering command and a command value (object yaw rate) from the cruise control ECU 100 , and the brake control ECU 10 performs either of the aforementioned “2-BDC control” and “B-STR control”. At this time, it is checked whether there are, in a command receiving area of the memory for DMA transfer, a brake steering command and command values (lane deviation amount and curve radius) from the cruise control ECU 100 . When they exist, an object yaw rate yawO is computed on the basis of the command values, and an object yaw rate of the wheel brake pressure distribution control, which has been generated by the ECU 10 for “2-BDC control” and “B-STR control”, is corrected (biased) by an amount corresponding to the object yaw rate yawO for the brake steering, which has been commanded by the cruise control ECU 100 , thereby determining the wheel brake pressure distribution in response to the corrected object yaw rate. By this, a brake steering intended by the cruise control ECU 100 is implemented by the brake control ECU 100 .
When both “2-BDC control” and “B-STR control” are unnecessary, if the brake steering command and the common values are received from the cruise control ECU 100 , the brake control ECU 10 implements the wheel brake pressure distribution control only for this brake steering. Content of this is shown in FIG. 8 and described later. In the brake control ECU 10 , the detection signals of the sensors, the switches, etc. are read at a predetermined cycle, a predetermined data processing is performed, and information representing the computed or processed data and the determined control mode are written in the data storage area, which is addressed to the cruise control ECU 100 , of the memory for DMA transfer. The cruise control ECU 100 can read the data in the above area by using the DMA transfer when desired.
The main function of the cruise control ECU 100 is a cruise control (fixed speed running control/inter-vehicle distance control) and a lane deviation control.
In FIG. 3, the gist of the processing function of the cruise control ECU 100 is shown. When an operating voltage is applied, the cruise control ECU l 00 sets a built-in register, an input/output port and a built-in timer to their initial states, and sets an input/output interface of the ECU 10 to an input read connection and an output signal level when waiting (step 1).
A timer Tc for determining a control processing cycle is started (2), a processing from a operation board input read (3) to “data renewal of DNA memory” (7) is implemented, a time-over of the timer Tc is waited (8) and during waiting, a state of electric circuit in the ECU 100 is checked (9), thereby judging whether there is an abnormality (10). If there is no abnormality and the time-over of the timer occurs, the timer is started again (2), a processing from an operation board input read (3) to “data renewal of DMA memory” (7) is implemented. Thus, if an electric circuit in the ECU 100 has no abnormality, the steps 2-10 are repeatedly implemented substantially at the Tc cycle.
If a state (open, close) of switch operated by the driver is read in the operation board input read (3), state information and data, which are referenced in a later-mentioned cruise control (5) and “lane deviation control processing” (6), are read, by DMA transfer, from the GPS information ECU 190 , the image processing ECU 140 and the brake control ECU 10 (4). That is, data in a data write area, which is addressed to the cruise control ECU 100 , on a memory for DMA transfer within the above ECUs 190 140 , 10 is written, by DMA transfer, in a memory for DMA transfer in the cruise control ECU 100 , and is read therefrom and written in a reference memory (RAM) for data processing.
Next, “cruise control processing” (5) is implemented. Here, when a fixed speed running instruction switch of the operation/display board 110 is switched from OFF to ON, a vehicle speed at that time (vehicle speed data computed by the brake control ECU 10 ) is written in an object vehicle speed register. Until the fixed speed running instruction switch is switched to OFF or a fixed speed running release condition is brought into existence, an open/close control for a main throttle valve of engine is performed via the throttle control ECU 80 in such a manner that the vehicle speed coincides with an object vehicle speed (data of the object vehicle speed register). When an inter-vehicle distance control instruction switch of the operation/display board 110 is switched from OFF to ON, until it is switched to OFF or an inter-vehicle distance control release condition is brought into existence, an open/close control for a main throttle valve of engine is performed via the throttle control ECU 80 in such a manner that a distance between a preceding vehicle and the concerned vehicle, which has been detected by the image processing ECU 140 , becomes a distance corresponded to the vehicle speed. Incidentally, these controls are realized by repeatedly implementing “cruise control processing” (5) at the constant Tc cycle. Until the aforementioned fixed speed running control or intra-vehicle distance control is started and it is released, in the ECU 100 , a state information (“1”) representing the fact that it is being implemented is maintained in a cruise state register.
After passing through “cruise control processing” (5), the ECU 100 implements “lane deviation control processing” (6). Contents of this are shown in FIGS. 4-6. Next, contents of controls are realized by repeatedly implementing “lane deviation control processing” (6) at the constant cycle Tc.
1. Brake steering yes/no testing ( 21 - 41 in FIG. 4 ):
1A: If a deviation alarm main SW becomes ON by the driver, it is judged that the brake steering is yes ( 21 in FIG. 4 ), and the process proceeds to deviation alarm testing yes/no testing ( 42 - 45 ) in FIG. 5 .
1B: When the deviation alarm main SW is OFF, it is checked whether a state information of the cruise state register is 1 (cruise is being implemented) ( 22 in FIG. 4 ), and if the cruise is being implemented, it is judged that the brake steering is yes, and the process proceeds to the deviation alarm yes/no testing ( 42 - 45 ) in FIG. 5 .
1C: If the cruise is being implemented, data which has been read in the step 4 and represents a GPS position measurement valid/invalid of the GPS information processing ECU 190 is checked ( 23 ), and when it is valid, it is checked whether the read information means a cruise permission road ( 24 ). If this is yes, the process proceeds to the deviation alarm yes/no testing ( 42 - 45 ) in FIG. 5 . Whether it is the cruise permission read or not is determined by the read information written in a map data base and does not mean whether the cruise is officially permitted or not.
1D: When the GPS position measurement is invalid and when, even if it is valid, the cruise permission is not contained in the read information, data which has been read in the step 4 and represents a lane detection valid/invalid of the image processing ECU 140 is checked ( 25 ), and when the lane detection is valid, it is checked whether a curve radius R is larger than 900 m ( 26 ). And if the curve radius R is larger than 900 m, its continuation time is measured ( 26 b-c ). If the continuation time becomes longer than five minutes ( 26 e - 26 g ), the process proceeds to the deviation alarm yes/no testing ( 42 - 55 ) in FIG. 5 .
1E: When the lane detection is invalid and when, even if it is valid, the curve radius R is less than 900 m, it is checked whether a vehicle speed which has been read in the step 4 and computed by the brake control ECU 10 is higher than 60 Km/h ( 27 ). If it is higher than 60 Km/h, its continuation time is measured ( 28 - 30 ). If the continuation time becomes longer than five minutes ( 31 - 33 ), it is judged that the brake steering is yes, and the process proceeds to the deviation alarm yes/no testing ( 42 - 55 ) in FIG. 5 .
1F: When the deviation alarm main SW is OFF, the cruise is not implemented, the GPS position measurement data is invalid or the cruise permission is not contained in the read information even if that data is valid, a road whose curve radius is larger than 900 m does not continue for a time longer than five minutes even if the lane detection is invalid and the vehicle speed higher than 60 Km/h does not continue for a time longer than five minutes, it is judged the brake steering is no, and the process does not proceed to the deviation alarm yes/no testing ( 42 - 45 ) in FIG. 5 .
When this judgment to the effect that the brake steering is not is concluded, there may be such a case that an alarm has been already emitted or further the brake steering has been started by the deviation alarm yes/no testing ( 42 - 45 ) and an output setting ( 61 - 72 ), which are mentioned later. If it is so, when the judgment to the effect that the brake steering is no is concluded, the alarm is released and the brake steering is stopped.
1G: That is, state registers VcF, RcF, LcFT and RcFT for monitoring the aforementioned continuation time are first cleared ( 34 , 35 ). This brings about stoppage of the continuation time measurement. Next, all alarm flags (data of state register) are made OFF ( 36 ) and the all alarms are released ( 37 ). Whether the brake steering is being implemented or not is checked by a state register CcF ( 38 ). If the brake steering is being implemented a brake steering stoppage is commanded to the brake control ECU 10 ( 39 ), and a release alarm for informing a control release is displayed on the operation/display board 20 and setting for energizing a buzzer under a release alarm mode is performed. The state register CcF is cleared ( 41 ). Incidentally, when this release alarm is set, a timer is started, and thereafter if a time-over of this timer occurs the alarm is set, a timer is started, and thereafter if a time-over of this timer occurs, the alarm is stopped.
2. Deviation alarm yes/no testing ( 42 - 55 ):
2A: Data representing a lane detection valid/invalid of the image processing ECU 140 is checked. If the lane detection is invalid, since there is no lane deviation amount data or a low reliability, the process proceeds to a brake steering release yes/no testing ( 56 - 60 in FIG. 6) jumping the deviation alarm yes/no testing.
If the detection is valid, a lane deviation amount which is being computed by the image processing ECU 140 is checked ( 43 , 45 ). As mentioned before, the lane deviation amount is one having a larger value among the left-side deviation amount [(Vw/2)−XL] and the right-side deviation amount [(Vw/2)−XR]. In the lane deviation amount data, there are contained a deviation amount numeric value data (including+m, −) and a direction data which indicates whether the deviation is left-side or right-side. If the lane deviation amount is larger than 0 m (vehicle's side edge exists on a lane partition line or protrudes therefrom), 1 (primary alarm yes) is written in a primary alarm flag register ( 44 ). If the lane deviation amount is below −0.3 m (position in which vehicle's side edge withdraws from the lane partition line by more than 3 m), the primary alarm flag register is cleared ( 46 ). By this, when the deviation amount becomes more than 0 m, the primary alarm flag goes ON (data of the primary alarm flag register=1). If the deviation amount becomes below −0.3 m, the primary alarm flag becomes OFF (data of the primary alarm flag register=0). If the deviation amount is less than 0 in but above −0.3 m, data of the primary alarm flag register is not changed.
2B: If the lane deviation amount becomes more than 1 m, 1 is written in a secondary alarm flag register ( 47 , 48 ). If the lane deviation amount is below 0 m, the secondary alarm flag register is cleared ( 49 , 50 ). By this, when the deviation amount becomes more than 1 m, the secondary alarm flag becomes ON. If the deviation amount becomes below 0 m, the secondary alarm flag becomes OFF. If the deviation amount is less than 1 m but above 0 m, data of the secondary data of the secondary alarm flag register is not changed.
2C: When data of the secondary alarm flag register is 1, if the lane deviation amount becomes more than 2 m, 1 is written in a tertiary alarm register ( 51 - 53 ). When data of the secondary alarm flag register is 0, if the deviation amount becomes below 0 m, the tertiary alarm register is cleared ( 54 , 55 ). By this, if the lane deviation amount is increased and becomes more than 2 m after the secondary flag has become ON, the tertiary alarm flag becomes ON. If the lane deviation amount becomes below 0 m, the tertiary alarm flag becomes OFF. If the deviation amount is less than 2 m but above 0 m, data of the tertiary alarm flag register is not changed.
3. Brake steering release yes/no testing ( 56 - 60 in FIG. 6 ):
3A: It is checked whether a front wheel steering angle θ is an angle which is larger, by more than 10° C., than a steering angle responding to the vehicle speed v and the curve radius R, i.e., a steering angle A1 [v, R] for performing a running of the curve radius R at the vehicle speed v ( 56 , 57 ). If it is so, it is deemed that the driver is intentionally steering (e.g., in order to avoid another vehicle, obstacle, etc. or to change a traffic lane), and it is judged that the brake steering release is yes and the process proceeds to the release processing ( 34 - 41 ) subsequent to step 34 . Content of this release processing is as described in the aforementioned 1G.
3B: It is checked whether a steering torque of front steering mechanism is above 2 Nm ( 58 ).
It if is so, it is deemed that the driver is intentionally performing a strong steering operation, and it is judged that the brake steering release is yes and the process proceeds to the release processing ( 34 - 41 ) subsequent to step 34 .
3C: State of turn signal SW of a turn signal driver 130 is checked ( 59 ). If it is ON (turn signal drive), it is judged that the brake steering release is yes and the process proceeds to the release processing ( 34 - 41 ) subsequent to step 34 .
3D: State of brake SW 45 is checked ( 60 ). If it is ON (brake pedal is applied), it is judged that the brake steering release is yes and the process proceed to the release processing ( 34 - 41 ) subsequent to step 34 . When there is no driver's steering operation, the turn signal is OFF and the brake SW is OFF, it is judged that the brake steering release is no and the process proceed to a brake steering alarm output ( 61 - 72 ) subsequent to step 61 .
4. Brake steering alarm output:
4A: When only the primary alarm flag is ON, i.e., when only the primary alarm flag within the primary to tertiary alarm flag register is 1, a primary alarm is displayed on the operation/display board 110 m, and the buzzer 120 is energized under a primary alarm mode 50 as to sound ( 61 - 64 ). Incidentally, this primary alarm continues until data of the primary alarm flag register is cleared, i.e., until the primary alarm flag becomes OFF.
4B: When the secondary flag is ON, the alarm is changed to the secondary alarm. That is, the secondary alarm is displayed on the operation/display board 110 , and the buzzer 120 is energized under a secondary mode so as to sound ( 62 , 65 ). This secondary alarm continues until the alarm flag register is cleared, i.e., until the secondary alarm flag becomes OFF.
If changed to the secondary alarm, it is checked whether the brake steering is being implemented (data of the register CcF is 1) ( 66 ). If the brake steering is not being implementation (CcF=0), the travelling direction correction, i.e., the brake steering is started ( 67 ). Since an actual brake steering (increase in wheel brake pressure and distribution control) is performed by the brake control ECU 100 , here the cruise control ECU 100 writes a correction command [a wheel brake pressure control instruction, a lane deviation amount (value containing+,− or right-side) and a curve radius] in a data area, which is addressed to the brake control ECU 10 , of the memory for DMA transfer. The cruise control ECU 100 writes 1 (the brake steering is being implemented) in the register CcF ( 68 ). The brake control ECU 10 increases the wheel brake pressure and performs the distribution control in response to the above correction command. That is, the brake steering is performed. Content of this is described later by referring to FIG. 8 .
4C: When the tertiary alarm flag became ON, the secondary alarm flag is cleared ( 69 , 70 ), a control stoppage alarm is displayed on the operation/display board 110 , and the buzzer 120 is energized under a stoppage alarm and an alarm timer which prescribes a time of this stoppage alarm is started ( 71 ). Thereafter, since the tertiary flag is ON and the secondary alarm flag is OFF, a time-over of the alarm timer is waited ( 72 ) and if the time-over occurs, the process proceeds to the release processing ( 34 - 41 ) subsequent to the step 34 . That is, if the tertiary alarm flag becomes ON (the lane deviation amount is more than 2 m), the stoppage alarm is firstly generated in order to stop the direction correction by the brake steering and thereafter the brake steering is stopped after the set time has elapsed. In FIG. 7, there is shown an outline of processing function of the brake control ECU 10 . If an operating voltage is applied, the brake control ECU 10 sets a built-in register, an input/output port and a built-in timer to initial states, and sets an input/output interface to an input read connection and an output signal level during waiting (step 81 ).
A timer Tb for determining a control processing cycle is started ( 82 ), a processing from an input read ( 83 ) “data renewal of DMA memory” ( 87 ) is implemented and a time-over of the timer Tb is awaited ( 88 ). During waiting, a state of electric circuit within the ECU 10 is checked ( 89 ) and it is judged whether there is an abnormality or not ( 90 ). If there is no abnormality and the time-over of the timer Tb occurs, the timer Tc is started again ( 82 ), and a processing from an input read ( 83 ) to “data renewal of DMA memory” ( 87 ) is implemented. Thus, if there is no abnormality in the electric circuit within the ECU 10 , steps 82 - 90 are repeatedly implemented substantially at a Tb cycle.
At the input read ( 83 ), if input of the operation/display board 20 and detection signals of the sensors 41 - 45 . YA, θF, θR, ST, GX and GY are read, a state information referenced at a brake control processing ( 85 ) and “direction correction processing” ( 86 ), which are mentioned later, and data are read from the cruise control ECU 100 by DMA transfer ( 84 ). That is, data in a data write area, which is addressed to the brake control ECU 10 , in a memory for DMA transfer within the ECU 100 is written in a memory for DMA transfer within the brake control ECU 10 , and is read therefrom and written in a reference data memory (RAM) for data processing.
Next, “brake control processing” ( 85 ) is implemented. Content of this is similar to one disclosed in the aforementioned Japanese Patent Unexamined Publication No. 8-207737. However, in the present embodiment, when the wheel brake pressure control of either of “2-BDC control” and “B-STR control” is performed, if data of the flag register CpF is 1 (direction correction demand from the ECU 10 is received), an object yaw rate yawO for brake steering is computed on the basis of command values (lane deviation amount, curve radius R) from the ECU 100 . An object yaw rate of the wheel brake pressure distribution control, which has been formed by the ECU 100 for “2-BCD control” and “B-STR control”, is corrected (biased) by an amount of the yaw rate yawO for brake steering instructed by the cruise control ECU 100 , thereby determining a wheel brake pressure distribution in response to the corrected object yaw rate. By this, a brake steering intended by the cruise control ECU 100 is implemented by the brake control ECU 10 . The object yaw rate yawO for brake steering is computed by a computation similar to that in steps 105 - 107 mentioned later.
After passing through “brake control processing” ( 85 ), the ECU 10 proceeds to “direction correction processing” ( 86 ). One mode of this content is shown in FIG. 8 . Here, the ECU 10 checks whether data of the flag register CpF is 1 (direction correction command from the ECU 100 has been already received) ( 101 ). If data of the flag register CpF is 0, it is checked whether there are a brake steering command and command values (lane deviation amount, curve radius R) from the cruise control ECU 100 ( 102 ). When they exist, 1 is written in the flag register CpF ( 103 ) and a measurement (clocking) of elapsed time T is started ( 104 ). On the basis of the lane deviation amount (+, −numeric value and deviation direction) and the curve radius R, an object yaw rate yawO of the brake steering for decreasing the lane deviation amount is computed ( 105 - 107 ).
That is, by making reference to a direction data of the lane deviation amount data (+1−value data and deviation direction data), a yaw rate generated by a change of the vehicle travelling direction along which the deviation amount is decreased and a yaw rate yawS for correction in the same direction are determined ( 106 A, 106 B). In the present embodiment, a value (absolute value) of yaw rate (yawS) for correction is determined to ±2°/sec. Next, from the determined yaw rate yawS for correction, a swing yaw rate yawS.(1+sin ωτ) which fluctuates within ±yawS is determined. A sum yawO=(v/R)+yawS (1+sin ωτ) of a vehicle speed v (m/sec) and a yaw rate (v/R), i.e., a yaw rate (v/R) which is inferred that it is generated under the running state at present, is made an object yaw rate for brake steering ( 107 ). The mark τ is a clocked value (elapsed time) of clocking started in the step 104 . ω is expressed as X=2πf, and f is decided as f=1 Hz in the present embodiment.
Next, it is checked whether data of a register ObsF is 1 (“2-BDC control” or “B-STR control” is being implemented) ( 108 ). When data of the register ObsF is 1, since the brake steering by an amount of the object yaw rate yawO in the aforementioned “brake control processing” ( 85 ) implemented just before the present processing or after the Tb is implemented as mentioned before, “brake control processing” ( 85 ) which is being implemented in this time ceases.
When data of the register ObsF is 0, since the wheel brake pressure control only for brake steering is necessary, a control duty amount is computed ( 109 ). A computation expression is shown in a block of the step 109 . In this computation expression, the duty (if it is a positive value) is an on-duty of repetition of open (ON=turning on electricity: pressure increase) and close (OFF=no turning on electricity: hold) of a pressure intensifier electromagnetic valve by which a pump discharge pressure is applied to the wheel brake, Kp is a proportional coefficient given to control error amount, yawO is an object yaw rate, Y is a detection value of yaw rate sensor YA, (yawO-Y) is a control error amount and Kd is a proportional coefficient (differential term coefficient) given to differential value d yawO/dt (change speed) of the object yaw rate.
That is, by PD control, the duty for adapting the yaw rate Y of vehicle, to the object yaw rate yawO is computed. On the basis of a direction of the lane deviation and a polarity of the duty, a wheel brake to be pressure-increased is determined. The pressure intensifier electromagnetic valve connected to the determined wheel brake is subjected to ON/OFF in a time series pattern realizing that duty ( 113 - 116 ). By this, with an average of comparatively long time in time series, only a left-front or right-front wheel brake is pressure-increased. When the left-front wheel brake in pressure-increased, the vehicle's travelling direction changes in left direction and when the right-front wheel brake is pressure-increased, it changes in right direction, so that the lane deviation amount is decreased (the vehicle moves toward a lane center). Moreover, with a comparatively short time (instantaneous value) in time series, the traveling direction fluctuates in response to yawS·(1+sin ωτ), so that a yaw rate vibration (lateral acceleration) is applied to the driver. This gives an abnormal feeling to the driver and becomes an incentive to pay attention.
For example, if the deviation direction is right, a brake steering for correcting the vehicle travelling direction to left direction is necessary, and the brake steering to left direction can be realized by pressure increase (duty value plus) of the left-front wheel brake or pressure decrease (duty value minus) of the right-front wheel brake. In the present embodiment, when the brake steering is necessary, since a wheel brake pressure by the brake pedal application does not exist (brake steering during the brake pedal application is not implemented: no brake pressure exists in wheel brakes 51 - 54 ), a practical effect of the brake steering by pressure decrease of the wheel brake cannot be expected. Thus, when it becomes a judgment to the effect that the right-front wheel brake should be pressure-decreased, the left-front wheel brake is pressure-increased ( 113 ). When it is judged that the pressure increase of either of the wheel brakes is necessary, the ECU 10 drives a brake oil pump of the wheel brake fluid circuit 30 . This is common to “brake control processing” ( 85 ) and “direction correction processing” ( 86 ).
In the step 101 , when it is recognized that data of the register CcF is 1 (brake steering is being implemented), the ECU 10 checks whether the cruise control ECU 100 outputted a direction correction release command ( 117 ). If it does not exist and there are a brake steering command and command values (lane deviation amount, curve radius R), the brake steering control ( 105 - 116 ) subsequent to the aforementioned step 105 is implemented.
If the cruise control ECU 100 outputs the direction correction release command, the ECU 10 clears the register CcF ( 118 ) and checks data of the register ObsF ( 119 ). When it is 1 (“2-BDC control” or “B-STR control” is being implemented), the release process ceases at this point of time. In this case, since the register CpF is cleared, when the wheel brake pressure control of either of “2-BDC control” and “B-STR control” is performed in “brake control processing” ( 85 ) implemented subsequently, data of the flag register CpF is 0 (there is no direction correction command from the ECU 100 ), so that the object yaw rate yawO for brake steering is not computed, and a wheel brake pressure distribution is determined in response to the object yaw rate itself of the wheel brake pressure distribution generated by the ECU 10 for “2-BDC control” and “B-STR control”.
When data of register ObsF is O (“2-BDC control” and “B-STR control” are not implemented), a pump drive is stopped and all electromagnetic valves are made OFF under the conditions that another “ABS control”, “TRC control” are not implemented, and the wheel brake oil circuit 30 is returned to a circuit connection which exerts only an output pressure of brake master cylinder to the wheel brake.
In the aforementioned embodiment, with the yaw rate Y being made a control amount, the wheel brake pressure distribution is controlled in such a manner that the yaw rate Y coincides with the object value yawO, but the control amount may be another physical value which becomes a value corresponding to the steering amount. For example, in the aforementioned embodiment, since the lateral acceleration sensor GY is provided, the lateral acceleration gy may be made a control amount. Further, it may be possible that the lateral acceleration is integrated to compute a lateral movement speed and the lateral movement speed is made a control amount. In any case, by making the yaw rate Y, the lateral acceleration gy and/or the lateral movement speed, each of which becomes a value corresponding to the steering amount, a control amount, a stable brake steering consistent with the vehicle's running state is realized.
As mentioned above, after passing through “brake control processing ( 85 ), the ECU 10 proceeds to “direction correction processing ( 86 ), and another mode of this content is shown in FIG. 9 . Here, the ECU 10 checks whether data of the flag register CpF is i (direction correction command from the Ecu 100 has been already received) ( 101 ). If data of the flag register CpF is O, it is checked whether there are a brake steering command and command values (lane deviation amount, curve radius R) from the cruise control ECU 100 . When they exist, 1 is written in the flag register CpF and, on the basis of the lane deviation amount (+,−numeric value and deviation direction) and the curve radius R, the brake steering object rate yawt for reducing this deviation is computed ( 105 ′- 106 ′). In this way, rate yawt becomes a value which is obtained by such a calculation that 2°/sec is added to or subtracted from a yaw rate (v/R) appearing with the vehicle speed v(m/sec) at that time and the curve radius R of running vehicle. The value 2°/sec is yaw rate adjustment allowance for reducing the deviation. It is checked whether data of the register ObsF is 1 (“2-BDC control” or “B-STR control” is being implemented) ( 108 ). When data of the register ObsF is 1, since the brake steering by an amount of the object yaw rate yawt is implemented in such a manner as mentioned before in the aforementioned “brake control processing” ( 85 ) implemented just before the present procession or after the Tb, “brake steering” ( 85 ) which is being implemented at present ceases.
When data of the register ObsF is 0, since the wheel brake pressure control only for brake steering is necessary, a control duty amount is computed ( 109 ). A computation expression is shown in a block of the step 109 . In this computation expression, the duty (if it is a positive value) is an on-duty of repetition of open (ON=turning on electricity: pressure increase) and close (OFF=no turning on electricity: hold) of a pressure intensifier electromagnetic valve by which a pump discharge pressure is applied to the wheel brake, Kp is a proportional coefficient given to control error amount, yawt in an object yaw rate, Y is a detection value of yaw rate sensor YA, (yawt−Y) is a control error amount and Kd is a proportional coefficient (differential term coefficient) given to differential value d yawt/dt (change speed) of the object yaw rate.
That is, by PD control, the duty for adapting the yaw rate Y of vehicle to the object yaw rate yawt is computed. On the basis of a direction of the lane deviation and a polarity of the duty, a wheel brake to be pressure-increased is determined. The pressure intensifier electromagnetic valve connected to the determined wheel brake is subjected to ON/OFF in a timed series pattern realizing that duty ( 113 - 116 ). By this, with an average of comparatively long time in time series, only a left-front or fight-front wheel brake is pressure-increased. When the left-front wheel brake is pressure-increased, the vehicle's travelling direction changes in left direction and when the right-front wheel brake is pressure-increased, it changes in right direction, so that the lane deviation amount is decreased (the vehicle moves toward a lane center).
For example, if the deviation direction is right, a brake steering for correcting the vehicle travelling direction to left direction is necessary, and the brake steering to left direction can be realized by pressure increase (duty value plus) of the left-front wheel brake or pressure decrease (duty value minus) of the right-front wheel brake. In the present embodiment, when the brake steering is necessary, since a wheel brake pressure by the brake pedal application does not exist (brake steering during the brake pedal application is not implemented: no brake pressure exists in wheel brakes 51 - 54 ), a practical effect of the brake steering by pressure decrease of the wheel brake cannot be expected. Thus, when it becomes a judgment to the effect that the right-front wheel brake should be pressure-decreased, the left-front wheel brake is pressure-increased ( 113 ). When it is judged that the pressure increase of either of the wheel brakes is necessary, the ECU 10 drives a brake fluid pump of the wheel brake oil circuit 30 . This is common to “brake control processing” ( 85 ) and “direction correction processing” ( 86 ).
In the step 101 , when it is recognized that data of the register CcF is 1 (brake steering is being implemented), the ECU 10 checks whether the cruise control ECU 100 outputted a direction correction release command ( 117 ). If it does not exist and there are a brake steering command and command values (lane deviation amount, curve radius R), the brake steering control ( 105 - 116 ) subsequent to the aforementioned step 105 is implemented.
If the cruise control ECU 100 outputs the direction correction release command, the ECU 10 clears the register CcF ( 119 ) and checks data of the register ObsF ( 119 ). When it is 1 (“2-BDC control” or “B-STR control” is being implemented), the release process ceases at this point of time. In this case, since the register CpF is cleared, when the wheel brake pressure control of either of “2-BDC control” and “B-STR control” is performed in “brake control processing” ( 85 ) implemented subsequently, data of the flag register CpF is 0 (there is no direction correction command from the ECU 100 ), so that the object yaw rate yawt for brake steering is not computed, and a wheel brake pressure distribution is determined in response to the object yaw rate itself of the wheel brake pressure distribution generated by the ECU 10 for “2-BDC control” and “B-STR control”.
When data of register ObsF is O (“2-BDC control” and “B-STR control” are not implemented), a pump drive is stopped and all electromagnetic valves are made OFF under the conditions that another “ABS control”, “TRC control” are not implemented, and the wheel brake fluid circuit 30 is returned to a circuit connection which exerts only an output pressure of brake master cylinder to the wheel brake.
In the aforementioned embodiment, if in the travelling direction correction yes/no testing ( 21 - 33 ) at lest one of the following conditions (a)-(e) is brought into existence, it is judged that the travelling direction correction is yes: (a) the deviation alarm main SW is ON, (b) the cruise control is being implemented, (c) the GPS position measurement data is effective and the cruise permission is contained in the read information, (d) the lane detection is effective and the curve radius of larger than 900 m continues for longer than five minutes and (e) the vehicle speed of higher than 60 Km/h continues for longer than five minutes. Although these five conditions are all equivalent, it may be possible to adopt a testing logic which judges that the travelling direction correction is yes when at least two of these five conditions are brought into existence. One example of this is shown in FIG. 10 .
In the example shown in FIG. 10, under a first condition that the deviation alarm main SW is ON, if at least one of the following conditions (i)-(iv) is brought into existence, it is judged that the travelling direction correction is yes: (i) the cruise control is being implemented, (ii) the GPS position measurement data is effective and the cruise control permission is contained in the read information, (iii) the lane detection is effective and the curve radius of larger than 900 m continues for longer than five minutes and (iv) the vehicle speed of higher than 60 Km/h continues for longer than five minutes. If the deviation alarm main SW is switched to OFF, the travelling direction correction is released ( 21 - 34 - 41 ). In this example, by existence of the first condition (deviation alarm SW is ON) and other of the four conditions, it is judged that the travelling direction correction is yes. It may be possible to adopt another combination. For example, it is judged that the travelling direction correction is yes when the above five conditions are all brought into existence.
In the mode shown in FIG. 10, since the travelling direction correction yes/no is first determined by the driver's will, such a possibility that whether the brake steering is performed or not performed is decided depending on the driver becomes high, so that a realization probability of the automatic detection of lane deviation and the brake steering corresponding to the deviation becomes low correspondingly. In case of a mode in which it is judged that the travelling direction correction is yes when all of the above five conditions are brought into existence, the realization probability becomes further low.
As shown in FIG. 4, in the mode in which it is judged that the travelling direction correction is yes when either of the five conditions is brought into existence, a probability that the brake steering corresponding to the lane deviation is automatically performed is high, and if a reliability of lane deviation detection and brake steering is high, an effect of preventing the vehicle from drifting from the lane due to the driver's carelessness (e.g., sleepiness or looking away) is high. However, such a possibility is also high that the brake steering acting against the driving intended by the driver occurs. In the aforementioned embodiment, a difference from the driving intended by the driver is sensed by the brake steering release testing of the steps 56 - 60 and the brake steering is released.
While the preferred embodiments have been described, variations thereto will occur to those skilled in the art within the scope of the present inventive concepts which are delineated by the following claims. | A travelling direction correcting apparatus includes: a shift detection device for detecting a shift amount of a vehicle running on a road with respect to the road; a wheel brake pressure control device for pressure wheel brake pressures and controlling a wheel brake pressure distribution; and a cruise control device for commanding a wheel brake pressure distribution control to the wheel brake pressure control device. The wheel brake pressure distribution control includes the following processes: (1) at least one of a yaw rate, a lateral speed and a lateral acceleration is made an index, (2) a value of the index, which appears in the vehicle when its running direction is changed toward a direction along which the shift amount decreases, is added to a value of the index, which appears when the vehicle runs along a curved road, and a summed amount is made an object value and (3) the value of the index, which appears in the vehicle, is coincided with the object value. | 88,932 |
REFERENCE TO RELATED APPLICATIONS
This is a continuation-in-part of U.S. patent application, Ser. No. 501,969, filed Aug. 30, 1974, now U.S. Pat. No. 3,897,950.
BACKGROUND OF THE INVENTION
The play of spiking is one of the most interesting in the game of volleyball and one for which volleyball players take great pleasure in establishing or setting and then completing. It involves more required coordination on the part of the spiking player than any other play in the sport and consequently is more difficult than any other play. Successful spiking requires that the ball be set, that is, lofted by a companion player into position such that it begins its descending arc almost vertically and in a position adjacent to the net and not over the net or accessible to defensive players. The spiker must be able to run or jump to meet the ball on its descending route, strike it while it is still above the level of the net and direct it over and downward into opposing territory.
The play of spiking when being set up is obvious to the opposing team which allows them as players, to assume defensive positions. This makes the art of spiking even more difficult since the spiking player must not only coordinate his move with that of the set ball, but he must be able to watch opposing players, analyze their defense and spike to avoid them.
Because the spiking step is one which involves a dynamic situation of both the ball and the spiking player as well as the defensive players, the training of spikers is difficult.
Spiking defense, on the other hand, involves one or more players jumping at the appropriate time and location, and presenting a barrier with their open hands and arms. If successful, the defense players cause a rebound at high velocity and unpredictable direction.
BRIEF STATEMENT OF THE INVENTION
I have discovered that it is possible to segregate the separate steps in spiking and thereby facilitate the training of volleyball players. I have segregated the steps of the actual spike from that of playing the set through the use of a device including a support and a pair of arms at adjustable height above the ground level. The arms include flexible holders which cradle the volleyball at the correct position for the learning player to spike. The device is adjustable in height to teach the effects of the height of the ball at the time of the spike and also it is useful in teaching defensive players how to combat the spike.
In its alternate embodiment, a substitute head for the spike training device is an array of spaced bars which, when struck with a spiked volleyball, will return the volleyball in an unpredictable direction and velocity depending upon its attitude when it is struck. This is comparable to the unpredictable nature of the block of a spike by a trained defensive player. It is adjustable in height and attitude as well.
In a second alternate embodiment, the substitute head for the training device includes an array of spaced bars which extend in a vertical direction as opposed to a horizontal direction. Likewise, the frame member supporting the vertical bars is slightly concave in order to provide a limit for lateral return of the ball.
BRIEF DESCRIPTION OF THE DRAWING
This invention may be more clearly understood by the following detailed description and by reference to the drawings in which:
FIG. 1 is a side elevational view of a spike training device in position for use;
FIG. 2 is an enlarged fragmentary front elevational view of the ball holding head of this invention;
FIG. 3 is a fragmentary vertical section to the support portion of the device of this invention;
FIG. 4 is a perspective view of an alternate embodiment of this invention;
FIG. 5 is a vertical section through the head of the embodiment of FIG. 4 taken along lines 5--5;
FIG. 6 is a side elevational view of a variation of the embodiment of FIG. 4;
FIG. 7 is a fragmentary sectional view of the apparatus of FIG. 6 taken along lines 7--7 of FIG. 6; and
FIG. 8 is a fragmentary side elevational view of the apparatus of FIGS. 6 and 7;
FIG. 9 is a perspective view of an alternate embodiment of this invention;
FIG. 10 is a top plan view of the operating head of the embodiment of FIG. 9;
FIG. 11 is a fragmentary top plan view of the embodiment of FIG. 9 shown in playing position; and
FIG. 12 is an enlarged fragmentary sectional view along lines 12--12 of FIG. 9.
DETAILED DESCRIPTION OF THE INVENTION
As indicated above, the object of this invention is to place a volleyball in certain positions for the training of spiking and of the defense to spiking. In spike training the volleyball is positioned in the region of the net and at a selected height so that the player may have a virtually unobstructed view of the net, opposing players or defensive devices, and the ball, and be able to strike the ball without interference just as in the case of actual play. Each of these requirements are met by the device of FIG. 1.
Now referring to FIG. 1, the volleyball training device includes a base 10 which may be merely the crutch tip type of base or, as shown in the drawing, a heavy base 10, sufficient to hold the device upright when in use. As is shown in the drawing, the base 10 is a hollow plastic body which may be filled with either sand or water to provide the necessary weight. It includes a recess 11 into which a support standard 12 is positioned. Extending in telescoping relationship with the support standard 12 is the operating head 13 which includes a pair of arms 14 and 15 having ball holders 16 and 20. The arm 15 is generally C shaped and constitutes an extension of the operating head 13 having sufficient height H and sufficient width W to provide a free clearance area for the player.
Now referring to FIG. 2 for the details of the ball support 16 and 20 where they may be more clearly seen, the support members 16 and 20 are preferably of all foam plastic such as polystyrene having tapered inward extending faces, 30 and 31 respectively. The supports 16 and 20 are of sufficient length to telescope over the ends of the arms 14 and 15. Therefore the entire region adjacent to the ball 17 has a soft plastic consistency to protect the hands of the spiker. The tapered surfaces 30 and 31 cradle the ball 17 and release it upon being struck by the spiker's hand. I have found that the use of foam plastic effectively cradles the ball 17, and the spiker hardly detects any support, particularly at the moment of impact. This simulates as closely as possible the ball in free flight at the time of spiking.
In accordance with this invention, the support 12 and operating head 13 are manufactured of anodized tubular aluminum. For example, its head exhibits a degree of flexibility and lightness in weight so that it may be easily moved and stored. In use, it is recommended that in addition to the support given by the base 10, a player hold the support standard 12 during use, to prevent overturning of the device in the event of a direct blow by an inexperienced player to the operating head. The holding person may well be trainer or coach who can readily observe at close hand the student spiker.
I have found that the device, in accordance with this invention, must be light weight to afford easy handling and storage and the arms 14 and 15 must exhibit a degree of flexibility to allow easy movement of the ball 17 from its support 16 and 20 without interference with the direction or velocity of the spiked ball. This requirement of flexibility is achieved employing aluminum tubing as specified above.
When subject to actual play, the points of greatest strain on the device are at the junction of the arms 14 and 15 in the operating head 13. I have found that the required flexibility in the operating head may be maintained while significant strength and resistance to permanent deformation or breakage may be accomplished in a manner as shown in FIG. 3. Now referring to FIG. 3, which is a sectional view at the intersection of the arms 14 and 15, the arm 14 is secured as by welding with the fillets apparent in the drawing. Within the tube 13, coextensive with the region of the intersection of arm 14 and 15, is an internal reinforcing tube 32 which is secured to the operating head 14 and arm 15 portion by a pair of machine bolts or other similar equivalent fasteners 33. In actuality, the stiffening member 32 and bolt 33 may also serve an additional function. That is that because of the size of the training device, it is sometimes desirable to segment it for storage. When such is the case, it is possible to have a seam between the arm 15 and the operating head 13 and between the bolts 33 and the stiffening member 32 which serves as an interconnecting member. In such case, the entire assembly may be reduced to approximately 1/3 of its maximum dimension as shown in FIG. 1. The principal purpose, however, of stiffening member 32 is to provide the strength for arms 14 and 15 while allowing the arms 14 and 15 per se to be flexible for light restraint on the ball 17.
At the bottom of the operating head 13 there is a locking device of the twist lock type which allows the standard 12 and operating head 13 to be telescoped and locked at the appropriate height by twisting parts 12 and 13 with respect to each other. A particularly desirable lock for this purpose is illustrated in U.S. Pat. Nos. 3,095,825 and 3,515,418. Suffice it to say the lock 34 is effective to securely bind the operating head 13 to the standard 12 at any desired height ready for use as illustrated in FIG. 1.
As indicated above, the training of a student spiker also allows the training of defensive players who position themselves on the opposite side of the net ready to attempt to block and return the spiked ball. When the defensive players are successful, the returned ball reflecting the high energy of a spiked ball and the closeness of the defensive players to the net allows the return ball to travel at high velocity in unpredictable direction.
Incorporating the substitute head for the assembly of FIG. 1, the simulation of a return spike may be accomplished. This defensive training device appears in FIG. 4.
Now, directing our attention to FIG. 4, you may see that the same base 10 in standard 12 is used, in this case, a substitute head 40 comparable to the operating head 13 portion of FIG. 1 being present. The operating head 40 includes a plurality of generally horizontally spaced bars 41 having a spacing therebetween less than the diameter of a volleyball. The use of spaced bars rather than a solid surface is truly significant to this invention. A simple reflective baffle board will serve to predictably return a ball. Players from the earliest ages have learned to detect that the angle of deflection of a ball striking a surface is approximately equal to the angle of incidence. Therefore, a truly representative condition cannot be achieved using a planar deflective surface. In this case, any spiked ball striking the device of FIG. 4 will strike either a single one of the bars 41, the upright 40 or its counterpart at the outer end 42. Striking a single or combination of the bars will result in a totally different direction of rebound. This is illustrated in FIGS. 6 and 7 showing an elevational view in FIG. 6 and a top view in FIG. 7. For example, if the operating bars 41 are in the exact vertical direction and the volleyball, as shown in FIG. 6, strikes midway between two adjacent bars, a direct return can be expected. However, any variation in the direction of incidence and the degree of impact on any one of the bars will unpredictably determine the rebound flight direction. This is true in both the vertical and horizontal planes.
In the case of the rebound trainer of FIG. 4, the bars are all in fixed vertical arrangement. It has been found desirable, however, to change the angle of the array of bars 41. This is accomplished, as illustrated in FIGS. 6, 7 and 8, wherein the operating head 40 has an auxiliary member 40a, best seen in FIG. 8. The bars 41 are fixed to member 40a instead of head 40 and a sector vertical adjustment member 44 engages the operating head 40 and its adjustable counterpart 40a. Thus, by simply loosening a wing nut 45 and changing the angle of section 44, the entire array may be adjusted in angularity and the total effect of an impacting ball is changed.
It is apparent that both training devices may be used simultaneously or separately and a single device with both the operating heads 13 and 40 may be used to alternately train spikers and defenders.
Now referring to FIG. 9, one may see an alternate embodiment of this invention employing a similar base 10 with a single upright member 12 supported in opening 11 of the base 10 and supporting an operating head 50 which may be pivoted by hinge assembly 51 or may be a single rigid assembly. The operating head includes a lower bar 52 and an upper bar 53 joined by end bars 54 and 55. The upper and lower bars 53 and 52 may be either acute or angular with the angle or center of arc generally at a. Joining the upper and lower bars 53 and 52 are a number of intermediate bars 56. The vertical members may be variable in number and variable in spacing provided the spacing between adjacent members is less than the diameter of a volleyball. In the drawing as shown, there are five vertical members 56 between the ends of 54 and 55 and there are all shown in a vertical array. It may be recognized that by bending the assembly at the hinge 51, the angle of attack and return may be changed for the device and further, that the bars 56 need not all be parallel.
One other feature which is apparent in FIG. 9 is that a single central support member is employed. This is, of course, an advantage over the embodiment of FIG. 4, where two supports are used with the resultant increase in total cost.
Of additional significance is the fact that the embodiment of FIG. 9 is not planar but with the angle, tends to return balls into the playing area. The angular form appears in FIG. 10.
Now referring to FIG. 10, the angularity of the operating head may be clearly seen. In the embodiment of FIG. 9, the device includes straight portions for the top and bottom members 53 and 52, of which top member 53 is visible and each side section 53a and 53b, offset by an angle A or B respectively. The angles A and B may be equal for a symetrical design or they may be different. I have found that the degree of angularity up to 20° is desirable to maintain the ball on the court, when in use, and also to provide a near reasonable simulation of actual play in spiking defense. This is particularly true since the spike defense player will not normally attempt to rebound the ball directly at the spiker, but to one side or the other.
The typical play angles are illustrated in FIG. 11 where at the top the spiker has spiked direct onto the operating head 50 over the net 21. The rebound is at an angle with respect to the net. Below, in FIG. 11b, in the position shown similar to that of FIG. 11a, an angular rebound which more or less matches the angle of deviation of the head, provides a near direct rebound. It must be taken into account that in addition to the effect of the angle of the head, the principal factor in determining the angle of rebound of the ball is the uncontrolled and random relationship that occurs depending upon whether the ball strikes directly between two upright figure members 56 as illustrated in FIG. 12, or strikes one bar in 56 alone, or any other intermediate possibility. Therefore, the spiker cannot really predict where the return will be, adding to the effective training of the spiker.
As is fairly apparent from a comparison of the blocking devices of FIG. 4 and FIG. 9, the device of FIG. 4 illustrated in FIG. 7, generally produces a return of the spike which deviates from the angle of incidence principally in the vertical plane, while the device of FIG. 9 provides principally lateral deviation. By periodic exchange of heads, the training of the spiker may be enhanced. Also, employing the embodiment of FIG. 9, the change of angularity by action at the hinge 51 enhances the vertical displacement on rebound. In each embodiment, the operation is significantly superior to any planar surface device.
The above described embodiments of this invention are merely descriptive of its principles and are not to be considered limiting. The scope of this invention instead shall be determined from the scope of the following claims, including their equivalents. | A device for assisting in the training of volleyball players to learn the art and defense to the play known as spiking. This device is a holder for a volleyball at selected elevations near the volleyball net or a rebound surface. The holder allows a player to run, jump and strike the ball in a manner to drive it with great energy over the net and into opposing team's territory. The rebounder deflects a spiked ball in an unpredictable direction. The rebounder comprises a plurality of arms spaced less than a volleyball diameter apart and constituting an operating head. The operating head is positioned adjustably by a standard, whereby it may be located above and adjacent to a volleyball net to deflect unpredictably volleyballs spiked against it, for training of the defense to volleyball spiking. | 16,867 |
This is a continuation-in-part application of Ser. No. 280,816, filed July 6, 1981, now abandoned.
FIELD OF THE INVENTION
This invention relates to s-triazin-2-one and thione compounds, processes for their preparation, intermediates useful in their preparation, pharmaceutical compositions and methods for influencing physiological function, such as blood pressure, in humans and animals.
REPORTED DEVELOPMENTS
1,3,5-triazine compounds are known to possess a broad spectrum of biological activity. The 4,6-diamino-1,2-dihydro-2-triazines have been reported to be effective as antimalarial, antitumor, antihelminthic and antibacterial agents as well as active agents against coccidiosis in chicks and against murine toxoplasmosis. See Heterocyclic Compounds, Volume 7, John Wiley & Sons, 1961 (Elderfield ed.) Chapter 8, "S-Triazines."
The antiherbicidal activity of 1-alkyl-4-alkylamino-1,2-dihydro-2-triazin-2-ones and thiones has been reported in U.S. Pat. No. 3,585,197 to Seidel et al. Recently, 1-aryl-1,2-dihydro-1,3,5-triazin-2-ones (thione) and their pharmacological uses have been reported in U.S. Pat. No. 4,246,409 to Douglas et al.
S-Triazin-2-ones (thiones) which are substituted by hydrazinyl groups in the 4-position have not been previously reported.
SUMMARY OF THE INVENTION
This invention relates to a class of s-triazine compounds according to Formula I ##STR2## wherein:
X is oxygen or sulfur;
R 1 is aryl, substituted aryl, aralkyl, heterocyclic, substituted heterocyclic, heterocyclic lower alkyl, or substituted heterocyclic lower alkyl;
R 4 is hydrogen, alkyl, cycloalkyl, alkenyl, alkynyl, alkanoyl, carboalkoxy, carbamoyl, alkyl carbamoyl, aryl, aroyl, aralkyl, heterocyclic, substituted heterocyclic, halo alkyl, or halo alkanoyl;
R 6 is hydrogen, alkyl, cycloalkyl, alkenyl, alkynyl or aralkyl; and the pharmaceutically acceptable acid addition salts thereof.
This invention relates also to processes for the preparation of compounds of Formula I and intermediate compounds useful in these processes.
Compounds within the scope of Formula I possess pharmaceutical activity, including cardiovascular activity, such as blood pressure lowering activity, and are useful in methods of treating physiological disorders, such as hypertension, in humans and animals.
DETAILED DESCRIPTION OF THE INVENTION
Depending upon the specific substitution, compounds of Formula I above may be present in enolized or tautomeric forms. Certain of the compounds can also be obtained as hydrates or in different polymorphic forms. The structures used herein to designate novel compounds are intended to include the compound along with its alternative or transient states. The nomenclature generally employed to identify the novel triazine derivatives as disclosed herein is based upon the ring structure shown in Formula I with the triazine ring positions numbered counterclockwise beginning with the nitrogen having the R 1 substitution.
Compounds of this invention which are preferred include those wherein:
X is oxygen or sulfur;
R 1 is phenyl or substituted phenyl;
R 4 is hydrogen, lower alkyl, lower alkanoyl, carboloweralkoxy, phenyl, or benzoyl;
R 6 is hydrogen or lower alkyl; and the pharmaceutically acceptable acid addition salts thereof.
A subclass of these compounds, of particular interest, includes compounds according to Formula I wherein:
X is oxygen or sulfur;
R 1 is phenyl or phenyl in which one or more of the phenyl hydrogens has been replaced by the same or different substituents selected from the group consisting of halo or lower alkyl;
R 4 is hydrogen;
R 6 is hydrogen or methyl; and the pharmaceutically acceptable acid addition salts thereof.
Another class of preferred compounds is where:
R 1 is phenyl, 2-halophenyl, 3-halophenyl, 4-halophenyl, 3,4-dihalophenyl, 3-trihalomethylphenyl or 2,6-diloweralkylphenyl;
R 4 is lower alkanoyl, benzoyl, or carboloweralkoxy;
R 6 is hydrogen; and the pharmaceutically acceptable acid addition salts thereof.
A further preferred class of compounds is where:
R 1 is phenyl or substituted phenyl;
R 4 is methyl; and
R 6 is hydrogen;
provided that when R 1 is substituted phenyl the phenyl substituent is either 3- or 4-halo, or 3-trihalo alkyl; and the pharmaceutically acceptable acid addition salts thereof.
A special embodiment of these preferred classes of compounds is where:
R 1 is phenyl substituted in either the meta or para positions by a halogen, for example, chloro; or where
R 1 is phenyl substituted in either or both of the meta or para positions by chloro when R 4 is other than methyl.
Another special embodiment of these preferred classes of compounds is where:
R 1 is phenyl, 4-loweralkyl phenyl or 4-loweralkoxy phenyl;
R 6 is hydrogen; and
R 4 is phenyl; and the pharmaceutically acceptable acid addition salts thereof.
An embodiment of this invention, of particular interest, is a 4-hydrazinyl traizinone according to Formula I wherein R 1 is a heterocyclic ring. The most preferred heterocyclic ring is pyridyl, and the exemplary subclass of the compounds according to this invention which includes the pyridyl ring is shown below in Formulae II-IV. ##STR3## wherein: n is zero to four;
R is alkyl, alkoxy, halo, cyano, amino, carbamoyl, alkylamino, or dialkylamino; and
X, R 4 and R 6 are as defined above.
The most preferred compounds according to this invention are listed in the following Table I.
TABLE I______________________________________Name M.P.______________________________________4-acetylhydrazino-1-phenyl-1,2-dihydro- 158° C.1,3,5-triazin-2-one4-ethoxycarbonylhydrazino-1-phenyl-1,2- 165-167° C.dihydro-1,3,5-triazin-2-one4-hydrazino-1-phenyl-1,2-dihydro-1,3,5- >245° C.triazin-2-one4-methylhydrazino-1-phenyl-1,2-dihydro- 182.5-133° C.1,3,5-triazin-2-one4-acetylhydrazino-1-(4-chlorophenyl)- 176-178° C.1,2-dihydro-1,3,5-triazin-2-one4-benzoylhydrazino-1-(4-chlorophenyl)- 193-195° C.1,2-dihydro-1,3,5-triazin-2-one1-(4-chlorophenyl)-4-ethoxycarbonyl- 194-195° C.hydrazino-1,2-dihydro-1,3,5-triazin-2-one1-(4-chlorophenyl)-4-hydrazino-1,2- >250° C.dihydro-1,3,5-triazin-2-one1-(4-chlorophenyl)-4-methylhydrazino- 228-231° C.1,2-dihydro-1,3,5-triazin-2-one4-acetylhydrazino-1-(3-chlorophenyl)- 140-144° C.1,2-dihydro-1,3,5-triazin-2-one1-(3-chlorophenyl)-4-hydrazino-1,2- >250° C.dihydro-1,3,5-triazin-2-one1-(3-chlorophenyl)-4-methylhydrazino- 219-221° C.1,2-dihydro-1,3,5-triazin-2-one4-hydrazino-1-(4-methylphenyl)-1,2- >250° C.dihydro-1,3,5-triazin-2-one1-(4-methylphenyl)-4-phenylhydrazino- 196° C.1,2-dihydro-1,3,5-triazin-2-one1-(2,6-dichlorophenyl)-4-hydrazino- >250° C.1,2-dihydro-1,3,5-triazin-2-one4-acetylhydrazino-1-(2-chlorophenyl)- 210° C.1,2-dihydro-1,3,5-triazin-2-one1-(2-chlorophenyl)-4-hydrazino-1,2- >250° C.dihydro-1,3,5-triazin-2-one1-(3,4-dichlorophenyl)-4-hydrazino >250° C.1,2-dihydro-1,3,5-triazin-2-one4-acetylhydrazino-1(3-dichlorophenyl)- 183-185° C.4-methylhydrazino-1-(3-trifluoromethyl- 199-201° C.phenyl)-1,2-dihydro-1,3,5-triazin-2-one4-acetylhydrazino-1-(3-trifluoromethyl- 142.5-164° C.phenyl)-1,2-dihydro-1,3,5-triazin-2-one4-hydrazino-6-methyl-1-phenyl-1,2- >250° C.dihydro-1,3,5-triazin-2-one1-(4-methylphenyl)-4-phenylhydrazino- 196° C.1,2-dihydro-1,3,5-triazin-2-one1-(4-methoxyphenyl)-4-phenylhydrazino- 170.5-171.5° C.1,2-dihydro-1,3,5-triazin-2-one______________________________________
As employed above and throughout the disclosure, the following terms, unless otherwise indicated, shall be understood to have the following meanings:
"Alkyl" means a saturated aliphatic hydrocarbon which may be either straight- or branched-chain. Preferred are lower alkyl groups which have up to about 6 carbon atoms, including methyl, ethyl and structural isomers of propyl, butyl, pentyl and hexyl.
"Cycloalkyl" means a saturated cyclic hydrocarbon, preferably having about 3 to about 6 carbon atoms, which may also be substituted with a lower alkyl group.
"Carbamoyl" means a radical of the formula ##STR4## where R may be hydrogen or lower alkyl.
"Alkenyl" means an unsaturated aliphatic hydrocarbon which may include straight or branched chains. Preferred groups have up to about 6 carbon atoms and may be vinyl and any structural and geometric isomers of propenyl, butenyl, pentenyl, and hexenyl.
"Alkynyl" means an unsaturated aliphatic hydrocarbon containing one or more triple bonds. Preferred groups contain up to about 6 carbon atoms and include ethynyl, propynyl, butynyl, pentynyl, and hexynyl.
"Aryl" means a radical of an aromatic group. The preferred aromatic groups are phenyl and substituted phenyl.
"Substituted phenyl" means a phenyl group in which one or more of the hydrogens has been replaced by the same or different substituents including halo, lower alkyl, halo lower alkyl, amino, acylamino, hydroxy, phenyl lower alkoxy, lower alkanoyl, carboloweralkoxy, acyloxy, cyano, halo lower alkoxy or lower alkyl sulfonyl.
"Aralkyl" means lower alkyl in which one or more hydrogens is substituted by aryl (preferably phenyl or substituted phenyl). Preferred groups are benzyl or phenethyl.
"Heterocyclic" or "heterocyclic ring" means a cyclic or bicyclic system having 1 to 3 hetero atoms which may be nitrogen, oxygen or sulfur, including oxazolidinyl, thiazolidinyl, pyrazolidinyl, imidazolidinyl, piperidyl, piperazinyl, thiamorpholinyl, 1-pyrrole, 2-pyrrole, 3-pyrrole, 2-furan, 3-furan, 2-thiophene, 3-thiophene, 2-tetrahydrothiophene, 3-tetrahydrothiophene, 1-imidazole, 2-imidazole, 4-imidazole, 5-imidazole, 2-oxazole, 4-oxazole, 5-oxazole, 2-thiazole, 4-thiazole, 5-thiazole, 1-pyrazole, 3-pyrazole, 4-pyrazole, 5-pyrazole, 1-pyrrolidine, 2-pyrrolidine, 3-pyrrolidine, 2-pyridyl, 3-pyridyl, 4-pyridyl, 2-pyrimidine, 4-pyrimidine, 5-pyrimidine, 6-pyrimidine, 2-purine, 6-purine, 8-purine, 9-purine, 2-quinoline, 3-quinoline, 4-quinoline, 5-quinoline, 6-quinoline, 7-quinoline, 8-quinoline, 1-isoquinoline, 3-isoquinoline, 4-isoquinoline, 5-isoquinoline, 6-isoquinoline, 7-isoquinoline, 8-isoquinoline, carbazole, trimethyleneethylenediaminyl, ethyleneiminyl and morpholinyl;
"Substituted heterocyclic" or "substituted heterocyclic ring" means a heterocycle in which one or more of the hydrogens on the ring carbons have been replaced by substituents as given above with respect to substituted phenyl.
Preferred heterocyclic rings are pyridyl, pyrimidyl, pyrazolyl, imidazolyl, furyl, thienyl, oxazolyl, thiazolyl, piperidyl, morpholinyl, oxazolidinyl, thiazolidinyl, pyrazolidinyl, imidazolidinyl, piperazinyl, thiamorpholinyl, trimethyleneethylenediaminyl and ethyleneiminyl.
The terms "halo" and "halogen" include all four halogens, namely, fluorine, chlorine, bromine and iodine. The halo alkyls, halophenyl and halo-substituted pyridyl include groups having more than one halo substituent which may be the same or different such as trifluoromethyl, 1-chloro-2-bromo-ethyl, chlorophenyl, 4-chloropyridyl, etc.
"Acyloxy" means an organic acid radical of lower alkanoic acid such as acetoxy, propionoxy, and the like.
"Lower alkanoyl" means the acyl radical or a lower alkanoic acid, including acetyl, propionyl, butyryl, valeryl, and stearoyl.
"Alkoxy" means the oxy radical of an alkyl group, preferably a lower alkyl group, such as methoxy, ethoxy, n-propoxy, and i-propoxy.
"Aroyl" means a radical of the formula ##STR5## wherein R is aryl. Preferred aroyl groups include benzoyl and substituted benzoyl.
The preferred "halo lower alkyl" group is trifluoromethyl.
The preferred "halo lower alkanoyl" group is trifluoroacetyl.
The compounds of this invention may be prepared by the general synthesis according to Scheme I: ##STR6##
A 1-R 1 -substituted-4-alkyl isobiuret is cyclized to the corresponding 1-R 1 -6-R 6 -4-alkoxy-1,2-dihydro-1,3,5-triazin-2-one by treatment with an R 6 substituted cyclizing reagent.
The group in the 4-position of the isobiuret, shown as O-alkyl, may be any suitable group which is capable of being displaced upon treatment of the cyclized product with a hydrazinyl reagent. The alkoxy groups, as shown in Scheme I, are preferred.
Condensation of the 4-alkoxy triazinone with an appropriately substituted hydrazine produces the 4-hydrazino adduct according to Scheme II: ##STR7##
Alternatively, the 4-methoxy-s-triazinone may be reacted with unsubstituted hydrazine thereby producing the 4-hydrazinyl triazinone which may be treated with an appropriate alkylating or acylating reagent such as an alkyl halide, alkyl triflate, alkanoyl halide, such as, benzyol halide, methyl halide, acetyl chloride, benzoylchloride, and result in the desired R 4 substitution.
The triazinthione compounds according to this invention are prepared by the same general route by utilizing the corresponding isothiobiuret as starting material.
The isobiuret (isothiobiuret) starting material may be prepared by any manner known to those skilled in the art. One process for the synthesis of these particular isobiurets (isothiobiuret) comprises the treatment of an O-alkylisourea (isothiourea), such as O-methyl-isourea, with an appropriately substituted isocyanate (isothiocyanate) according to Scheme III: ##STR8##
For example, O-methyl isourea may be prepared in situ by neutralizing O-methyl isourea hydrogen sulfate with one equivalent of base, such as sodium hydroxide, in a polar nonaqueous solvent, such as, THF or ethanol. The reaction media is dried before adding the isocyanate by addition of a drying agent such as sodium sulfate (Na 2 SO 4 ). The isocyanate is added to the reaction media dropwise and the isobiuret recovered by extraction and recrystallization.
The isocyanate may be prepared from primary alkyl amines or anilines by methods known to those in the art (e.g., reaction with phosgene or thiophosgene in the customary manner).
The cyclizing reagent may consist of an activated form of an acid amide or ortho ester or acyl derivative such as a Vilsmier reagent which will bring about acylation and ring closure of the isobiuret or isothiobiuret to give the corresponding s-triazinone or thione of the type described above.
The cyclizing reagent employed in the reaction can be any cationic reagent system capable of generating in the reaction mixture a stabilized carbonium ion having the oxidation state of an acid or acid amide. Since the cationic carbon is incorporated into the ring the choice of reagent will determine the R 6 substitution in the compounds of Formula I above. Thus, in the case of a dialkyl carboxylic acid amide dialkyl acetal, such as, dialkyl formamide dialkyl acetal, R 6 is hydrogen and the resulting triazine is unsubstituted in the 6-position; in the case where the acetamide derivative is used as the cyclizing reagent, R 6 is methyl and the resulting triazine is substituted in the 6-position, and so on.
In general, the preferred cyclizing reagents are the ortho esters of carboxylic acids of the Formula V: ##STR9## wherein: R 6 is hydrogen, or lower alkyl; and each of R 10 through R 12 are lower alkyl or halo lower alkyl. Exemplary ortho esters include triethylorthoformate and trimethylorthoacetate. Additional cyclizing reagents include the carboxylic acid amide dialkyl acetals, such as, dialkyl formamide dialkyl acetal, preferably, dimethyl formamide dimethyl acetal; dialkyl acetamide dialkyl acetals, preferably, dimethyl acetamide dimethyl acetal; dialkyl propionamide dialkyl acetal, preferably, dimethyl propionamide dimethyl acetal. Other carboxylic acid amide derivatives can also be used including substituted derivatives.
Other methylidene derivatives that can be used as the cyclizing reagent include the combination of an N,N-disubstituted carboxylic acid amide and any strong alkylating agent, preferably a strong methylating agent. Any of the strong alkylating agents known in the art such as methyliodide, methylfluorosulfonate, alkylmethane sulfonates, e.g., methylmethanesulfonate, and alkyl or dialkyl sulfates, e.g., dimethylsulfate can be suitably employed though dimethylsulfate is preferred owing to its ready availability. A cyclizing reagent of particular interest is a DMF-dimethylsulfate complex.
Reagents of the type shown in Formula V above are stable products which are commercially available or can be prepared in advance.
The cyclizing reaction can be carried out by simply combining the reactants in a suitable solvent at room temperature with stirring. The reaction time can be shortened by heating the reaction mixture or by using elevated pressure or both. The solvent selected should have a relatively high boiling point and low vapor pressure in order to permit the reaction mixture to be heated above 100° C. Dimethylformamide is a convenient solvent to use, particularly where the cyclizing reagent is a dimethylformamide derivative, though other organic solvents can also be used. The solvents that can be used include saturated and unsaturated hydrocarbons, aromatic solvents, alcohols such as methanol and ethanol, halogenated hydrocarbons such as chloroform, carbon tetrachloride, ethylene chloride, or others such as methyl acetate, ethyl acetate, acetonitrile, acetone, ether, acetamide, tetrahydrofuran and the like. Suitable mixtures of solvents can also be used. The reaction is preferably carried out under substantially anhydrous conditions though the presence of water can be tolerated. If small amounts of water are present, the effect can be offset by using an excess of the cyclizing reagent.
In carrying out the cyclizing reaction, the cyclizing reagent is preferably used in slight excess of the amount required as the stoichiometric equivalent of the isobiuret or isothiobiuret starting material. Reagent systems employing dimethyl sulfate are prepared as necessary for the cyclization or can be formed in situ in the reaction mixture by adding the reagent components to the reaction vessel in a suitable solvent or solvent mixture. When carrying out the cyclizing reaction with a reagent of the type shown in Formula V, it is preferred to use as starting material an acid addition salt of the isobiuret or isothiobiuret or alternatively, if the free base is used, then an acid, preferably a mineral acid such as hydrochloric acid, can be added to the reaction mixture. When a reagent system comprising a carboxylic acid amide and a strong alkylating agent is employed, the reagent is itself acidic and the reaction proceeds readily with the free base as starting material. In such instances it may be advantageous to add a proton scavenging solvent such as a tertiary amine, e.g., triethylamine or cyclic amines such as pyridine. Other miscible solvents can be used along with the preferred amines e.g., solvents such as triethanolamine, acetonitrile, ethanol, etc., though dimethyl formamide is preferred.
The conversion of most isobiurets and isothiobiurets to the corresponding s-triazine derivative can be achieved in from less than about 20 minutes to about 5 hours at temperatures on the order of 100° C. to 120° C. Higher or lower temperatures can be used if desired, and the reaction can be carried out at room temperature.
In most cases the cyclized end product can be recovered by filtering after direct crystallization from the reaction mixture particularly where the solvent has been chosen to facilitate recovery of the end product. Where the product does not readily crystallize, the novel s-triazinone derivatives can be conveniently isolated in the pure form by solvent extraction using any of the usual organic solvents which are not miscible with water such as: the hydrocarbons, for example, hexane; the chlorinated hydrocarbons, for example, chloroform or carbon tetrachloride; the aromatic solvents such as benzene, xylene, toluene, o-chloro-toluene and the like; ethers such as dioxane; ketones such as 2-pentanone, etc. The s-triazinone product is extracted into the solvent layer generally after stripping the solvent or concentrating the reaction mixture then shaking with an extracting composition of water and solvent and removing the solvent component, leaving the by-product in the aqueous layer. The product is recovered by evaporating off the solvent. If desired, the product can be further purified by recrystallizing from a suitable organic solvent such as those noted above. The selection of solvent is not critical and generally those solvents which are most readily available will be employed.
The compounds of this invention may be readily converted to their nontoxic acid addition salts by customary methods in the art. The nontoxic salts of this invention are those salts the acid component of which is pharmacologically acceptable in the intended dosages. Such salts would include those prepared from inorganic acids, and organic acids, such as, higher fatty acids, high molecular weight acids, etc. Exemplary acids include hydrochloric acid, hydrobromic acid, sulfuric acid, nitric acid, phosphoric acid, methane sulfonic acid, benzene sulfonic acid, acetic acid, propionic acid, malic acid, succinic acid, glycolic acid, lactic acid, salicylic acid, benzoic acid, nicotinic acid, phthalic acid, stearic acid, oleic acid, abietic acid, etc.
It is well known in the pharmacological arts that nontoxic acid addition salts of pharmacologically active amine compounds do not differ in activities from their free base. The salts merely provide a convenient solubility factor. Other salts, for example, quarternary ammonium salts, are prepared by known methods for quarternizing organic nitrogen compounds.
The following example shows the synthetic preparation of the hydrazinyl triazinone compounds described herein. It is to be construed as an illustration of the preparation of the compounds and not as limitations thereof.
EXAMPLE I
Preparation of 4-methylhydrazinyl-1-phenyl-1,2-dihydro-1,3,5-triazin-2-one
A. 4-Methyl-1-phenyl isobiuret
41.45 g of aqueous NaOH are added to a stirred suspension of O-methylisourea hydrogen sulfate (44.33 g) in 400 ml of THF while being cooled. After stirring at RT for 15 minutes, 200 g of anhydrous Na 2 SO 4 are added to the reaction mixture with continued stirring for one hour. Phenyl isocyanate (31.30 g) dissolved in THF (150 ml) is then added dropwise over a period of two hours. The mixture is filtered, concentrated, and the product crystallized from ethylacetate and hexane, to afford 41.10 g of the isobiuret, m.p. 86°-88° C.
B. 4-Methoxy-1-phenyl-1,2-dihydro-1,3,5-triazin-2-one
4-methyl-1-phenyl isobiuret (41.08 g) is dissolved in 212 ml of triethylorthoformate. The solution is heated to 110°-115° C. for approximately four hours with a stream of N 2 being passed over the reaction mixture to flush out evolved ethanol and the reaction mixture allowed to cool overnight. The reaction product is filtered, washed with hexane, and recrystallized from toluene, affording 16.43 g of the triazinone, m.p. 171°-173° C.
C. 4-Methylhydrazinyl-1-phenyl-1,2-dihydro-1,3,5-triazin-2-one
2.4 ml of methylhydrazine dissolved in 10 ml of absolute ethanol are added to a suspension of 4-methoxy-1-phenyl-1,2-dihydro-1,3,5-triazin-2-one (4.60 g) in 100 ml of absolute ethanol and stirred for one hour. The solid product is filtered, washed with ether and dried to give 3.10 g (63.1%) of 4-methylhydrazino-1-phenyl-s-triazin-2-one, m.p. 219° C.
The isobiurets listed in Table II may be substituted for 4-methyl-1-phenyl isobiuret in Example 1 to prepare the corresponding 4-methoxy-s-triazinones in Table III.
TABLE II
4-methyl-1-benzyl isobiuret
4-methyl-1-(2-methylphenyl)-isobiuret
4-methyl-1-(2-ethylphenyl)-isobiuret
4-methyl-1-(2,6-dimethylphenyl)-isobiuret
4-methyl-1-(2,6-diethylphenyl)-isobiuret
4-methyl-1-(2-chlorophenyl)-isobiuret
4-methyl-1-(3-chlorophenyl)-isobiuret
4-methyl-1-(4-chlorophenyl)-isobiuret
4-methyl-1-(2-chloro-6-bromophenyl)-isobiuret
4-methyl-1-(3,4-dihydroxyphenyl)-isobiuret
4-methyl-1-(3,4-dichlorophenyl)-isobiuret
4-methyl-1-(3,4-dimethoxyphenyl)-isobiuret
4-methyl-1-(3,5-dichlorophenyl)-isobiuret
4-methyl-1-(3,4-diacetoxyphenyl)-isobiuret
4-methyl-1-(3,4-diethoxyphenyl)-isobiuret
4-methyl-1-(2-pyridyl)-isobiuret
4-methyl-1-(3-pyridyl)-isobiuret
4-methyl-1-(4-pyridyl)-isobiuret
4-methyl-1-[2-(3-methylpyridyl)]-isobiuret
4-methyl-1-[2-(4-methylpyridyl)]-isobiuret
4-methyl-1-[2-(5-methylpyridyl)]-isobiuret
4-methyl-1-[2-(5-methylpyridyl)]-isobiuret
4-methyl-1-[2-(3-chloropyridyl)]-isobiuret
4-methyl-1-[2-(4-chloropyridyl)]-isobiuret
4-methyl-1-[2-(3-carbomethoxypyridyl)]-isobiuret
4-methyl-1-[2-(3-cyanopyridyl)]-isobiuret
4-methyl-1-[2-(3-methoxypyridyl)]-isobiuret
TABLE III
4-methoxy-1-benzyl-1,2-dihydro-1,3,5-triazin-2-one
4-methoxy-1-(2-methylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methoxy-1-(2-ethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methoxy-1-(2,6-dimethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methoxy-1-(2,6-diethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methoxy-1-(2-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methoxy-1-(3-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methoxy-1-(4-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methoxy-1-(2-chloro-6-bromophenyl)-1,2,-dihydro-1,3,5-triazin-2-one
4-methoxy-1-(3,4-dihydroxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methoxy-1-(3,4-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methoxy-1-(3,4-dimethoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methoxy-1-(3,5-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methoxy-1-(3,4-diacetoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methoxy-1-(3,4-diethoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methoxy-1-(2-pyridyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methoxy-1-(3-pyridyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methoxy-1-(4-pyridyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methoxy-1-[2-(3-methylpyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-methoxy-1-[2-(4-methylpyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-methoxy-1-[2-(5-methylpyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-methoxy-1-[2-(3-chloropyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-methoxy-1-[2-(4-chloropyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-methoxy-1-[2-(3-carbomethoxypyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-methoxy-1-[2-(3-cyanopyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-methoxy-1-[2-(3-methoxypyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
The 4-hydrazino-s-triazinones of Table IV may be prepared from the corresponding 4-methoxy-s-triazinones disclosed in Table III.
TABLE IV
4-hydrazino-1-benzyl-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-1-(2-methylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-1-(2-ethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-1-(2,6-dimethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-1-(2,6-diethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-1-(2-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-1-(3-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-1-(4-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-1-(2-chloro-6-bromophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-1-(3,4-dihydroxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-1-(3,4-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-1-(3,4-dimethoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-1-(3,5-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-1-(3,4-diacetoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-1-(3,4-diethoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-1-(2-pyridyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-1-(3-pyridyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-1-(4-pyridyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-1-[2-(3-methylpyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-1-[2-(4-methylpyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-1-[2-(5-methylpyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-1-[2-(3-chloropyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-1-[2-(4-chloropyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-1-[2-(3-carbomethoxypyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-1-[2-(3-cyanopyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-1-[2-(3-methoxypyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-1-benzyl-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-1-(2-methylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-1-(2-ethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-1-(2,6-dimethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-1-(2,6-diethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-1-(2-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-1-(3-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-1-(4-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-1-(2-chloro-6-bromophenyl)-1,2-dihydro-1,3,5-triazin-2-on
4-methylhydrazino-1-(3,4-dihydroxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-1-(3,4-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-1-(3,4-dimethoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-1-(3,5-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-1-(3,4-diacetoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-1-(3,4-diethoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-1-(2-pyridyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-1-(3-pyridyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-1-(4-pyridyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-1-[2-(3-methylpyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-1-[2-(4-methylpyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-1-[2-(5-methylpyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-1-[2-(3-chloropyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-1-[2-(4-chloropyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-1-[2-chloro-6-bromophenyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-1-[2-(3-cyanopyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-1-[2-(3-methoxypyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-acetylhydrazino-1-benzyl-1,2-dihydro-1,3,5-triazin-2-one
4-acetylhydrazino-1-(2-methylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-acetylhydrazino-1-(2-ethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-acetylhydrazino-1-(2,6-dimethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-acetylhydrazino-1-(2,6-diethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-acetylhydrazino-1-(2-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-acetylhydrazino-1-(3-chlorophenyl)-1,2,-dihydro-1,3,5-triazin-2-one
4-acetylhydrazino-1-(4-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-acetylhydrazino-1-(2-chloro-6-bromophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-acetylhydrazino-1-(3,4-dihydroxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-acetylhydrazino-1-(3,4-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-acetylhydrazino-1-(3,4-dimethoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-acetylhydrazino-1-(3,5-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-acetylhydrazino-1-(3,4-diacetoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-acetylhydrazino-1-(3,4-diethoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-acetylhydrazino-1-(2-pyridyl)-1,2-dihydro-1,3,5-triazin-2-one
4-acetylhydrazino-1-(3-pyridyl)-1,2-dihydro-1,3,5-triazin-2-one
4-acetylhydrazino-1-(4-pyridyl)-1,2-dihydro-1,3,5-triazin-2-one
4-acetylhydrazino-1-[2-(3-methylpyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-acetylhydrazino-1-[2-(4-methylpyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-acetylhydrazino-1-[2-(5-methylpyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-acetylhydrazino-1-[2-(3-chloropyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-acetylhydrazino-1-[2-(4-chloropyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-acetylhydrazino-1-[2-(3-carbomethoxypyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-acetylhydrazino-1-[2-(3-cyanopyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-acetylhydrazino-1-[2-(3-methoxypyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-trifluoromethylhydrazino-1-benzyl-1,2-dihydro-1,3,5-triazin-2-one
4-trifluoromethylhydrazino-1-(2-methylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-trifluoromethylhydrazino-1-(2-ethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-trifluoromethylhydrazino-1-(2,6-dimethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-trifluoromethylhydrazino-1-(2,6-diethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-trifluoromethylhydrazino-1-(2-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-trifluoromethylhydrazino-1-(3-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-trifluoromethylhydrazino-1-(4-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-trifluoromethylhydrazino-1-(2-chloro-6-bromophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-trifluoromethylhydrazino-1-(3,4-dihydroxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-trifluoromethylhydrazino-1-(3,4-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-trifluoromethylhydrazino-1-(3,4-dimethoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-trifluoromethylhydrazino-1-(3,5-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-trifluoromethylhydrazino-1-(3,4-diacetoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-trifluoromethylhydrazino-1-(3,4-diethoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-trifluoromethylhydrazino-1-(2-pyridyl)-1,2-dihydro-1,3,5-triazin-2-one
4-trifluorometylhydrazino-1-(3-pyridyl)-1,2-dihydro-1,3,5-triazin-2-one
4-trifluoromethylhydrazino-1-(4-pyridyl)-1,2-dihydro-1,3,5-triazin-2-one
4-trifluoromethylhydrazino-1-[2-(3-methylpyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-trifluoromethylhydrazino-1-[2-(4-methylpyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-trifluoromethylhydrazino-1-[2-(5-methylpyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-trifluoromethylhydrazino-1-[2-(3-chloropyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-trifluoromethylhydrazino-1-[2-(4-chloropyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-trifluoromethylhydrazino-1-[2-(3-carbomethoxypyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-trifluoromethylhydrazino-1-[2-(3-cyanopyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-trifluoromethylhydrazino-1-[2-(3-methoxypyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-1-benzyl-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-1-(2-methylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-1-(2-ethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-1-(2,6-dimethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-1-(2,6-diethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-1-(2-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-1-(3-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-1-(4-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-1-(2-chloro-6-bromophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-1-(3,4-dihydroxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-1-(3,4-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-1-(3,4-dimethoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-1-(3,5-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-1-(3,4-diacetoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-1-(3,4-diethoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-1-(2-pyridyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-1-(3-pyridyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-1-(4-pyridyl)-1,2,-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-1-[2-(3-methylpyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-1-[2-(4-methylpyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-1-[2-(5-methylpyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-1-[2-(3-chloropyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-1-[2-(4-chloropyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-1-[2-(3-carbomethoxypyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-1-[2-(3-cyanopyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-1-[2-(3-methoxypyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-1-benzyl-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-1-(2-methylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-1-(2-ethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-1-(2,6-dimethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-1-(2,6-diethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-1-(2-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-1-(3-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-1-(4-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-1-(2-chloro-6-bromophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-1-(3,4-dihydroxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-1-(3,4-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-1-(3,4-dimethoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-1-(3,5-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-1-(3,4-diacetoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-1-(3,4-diethoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-1-(2-pyridyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-1-(3-pyridyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-1-(4-pyridyl)-1,2,-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-1-[2-(3-methylpyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-1-[2-(4-methylpyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-1-[2-(5-methylpyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-1-[2-(3-chloropyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-1-[2-(4-chloropyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-1-[2-(3-carbomethoxypyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-1-[2-(3-cyanopyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-1-[2-(3-methoxypyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-1-benzyl-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-1-(2-methylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-1-(2-ethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-1-(2,6-dimethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-1-(2,6-diethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-1-(2-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-1-(3-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-1-(4-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-1-(2-chloro-6-bromophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-1-(3,4-dihydroxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-1-(3,4-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-1-(3,4-dimethoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-1-(3,5-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-1-(3,4-diacetoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-1-(3,4-diethoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-1-(2-pyridyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-1-(3-pyridyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-1-(4-pyridyl)-1,2,-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-1-[2-(3-methylpyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-1-[2-(4-methylpyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-1-[2-(5-methylpyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-1-[2-(3-chloropyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-1-[2-(4-chloropyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-1-[2-(3-carbomethoxypyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-1-[2-(3-cyanopyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-1-[2-(3-methoxypyridyl)]-1,2-dihydro-1,3,5-triazin-2-one
The general synthesis described above may be utilized to prepare the 4-hydrazino-triazinones in Table V.
TABLE V
4-hydrazino-6-methyl-1-phenyl-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-6-methyl-1-phenyl-1,2-dihydro-1,3,5-triazin-2-one
4-ethylhydrazino-6-methyl-1-phenyl-1,2-dihydro-1,3,5-triazin-2-one
4-propylhydrazino-6-methyl-1-phenyl-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-6-methyl-1-phenyl-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-6-methyl-1-phenyl-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-6-methyl-1-phenyl-1,2-dihydro-1,3,5-triazin-2-one
4-propargylhydrazino-6-methyl-1-phenyl-1,2-dihydro-1,3,5-triazin-2-one
4-pyridylhydrazino-6-methyl-1-phenyl-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-6-methyl-1-(2-methylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-6-methyl-1-(2-methylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-ethylhydrazino-6-methyl-1-(2-methylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propylhydrazino-6-methyl-1-(2-methylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-6-methyl-1-(2-methylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-6-methyl-1-(2-methylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-6-methyl-1-(2-methylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propargylhydrazino-6-methyl-1-(2-methylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-pyridylhydrazino-6-methyl-1-(2-methylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-6-methyl-1-(2-ethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-6-methyl-1-(2-ethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-ethylhydrazino-6-methyl-1-(2-ethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propylhydrazino-6-methyl-1-(2-ethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-6-methyl-1-(2-ethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-6-methyl-1-(2-ethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-6-methyl-1-(2-ethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propargylhydrazino-6-methyl-1-(2-ethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-pyridylhydrazino-6-methyl-1-(2-ethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-6-methyl-1-(2-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-6-methyl-1-(2-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-ethylhydrazino-6-methyl-1-(2-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propylhydrazino-6-methyl-1-(2-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-6-methyl-1-(2-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-6-methyl-1-(2-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-6-methyl-1-(2-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propargylhydrazino-6-methyl-1-(2-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-pyridylhydrazino-6-methyl-1-(2-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-6-methyl-1-(3,4-dimethoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-6-methyl-1-(3,4-dimethoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-ethylhydrazino-6-methyl-1-(3,4-dimethoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propylhydrazino-6-methyl-1-(3,4-dimethoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-6-methyl-1-(3,4-dimethoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-6-methyl-1-(3,4-dimethoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-6-methyl-1-(3,4-dimethoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propargylhydrazino-6-methyl-1-(3,4-dimethoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-pyridylhydrazino-6-methyl-1-(3,4-dimethoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-6-methyl-1-(3,4-dihydroxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-6-methyl-1-(3,4-dihydroxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-ethylhydrazino-6-methyl-1-(3,4-dihydroxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propylhydrazino-6-methyl-1-(3,4-dihydroxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-6-methyl-1-(3,4-dihydroxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-6-methyl-1-(3,4-dihydroxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-6-methyl-1-(3,4-dihydroxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propargylhydrazino-6-methyl-(3,4-dihydroxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-pyridylhydrazino-6-methyl-(3,4-dihydroxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-6-methyl-1-(3-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-6-methyl-1-(3-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-ethylhydrazino-6-methyl-1-(3-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propylhydrazino-6-methyl-1-(3-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-6-methyl-1-(3-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-6-methyl-1-(3-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-6-methyl-1-(3-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propargylhydrazino-6-methyl-1-(3-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-pyridylhydrazino-6-methyl-1-(3-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-6-methyl-1-(4-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-6-methyl-1-(4-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-ethylhydrazino-6-methyl-1-(4-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propylhydrazino-6-methyl-1-(4-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-6-methyl-1-(4-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-6-methyl-(4-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-6-methyl-(4-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propargylhydrazino-6-methyl-(4-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-pyridylhydrazino-6-methyl-(4-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-6-methyl-1-(3,4-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-6-methyl-1-(3,4-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-ethylhydrazino-6-methyl-1-(3,4-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propylhydrazino-6-methyl-1-(3,4-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-6-methyl-1-(3,4-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-6-methyl-1-(3,4-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-6-methyl-1-(3,4-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propargylhydrazino-6-methyl-1-(3,4-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-pyridylhydrazino-6-methyl-1-(3,4-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-6-methyl-1-(2,6-diethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-6-methyl-1-(2,6-diethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-ethylhydrazino-6-methyl-1-(2,6-diethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propylhydrazino-6-methyl-1-(2,6-diethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-6-methyl-1-(2,6-diethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-6-methyl-1-(2,6-diethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-6-methyl-1-(2,6-diethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propargylhydrazino-6-methyl-1-(2,6-diethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-pyridylhydrazino-6-methyl-1-(2,6-diethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-6-methyl-1-(2,6-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-6-methyl-1-(2,6-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-ethylhydrazino-6-methyl-1-(2,6-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propylhydrazino-6-methyl-1-(2,6-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-6-methyl-1-(2,6-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-6-methyl-1-(2,6-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-6-methyl-1-(2,6-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propargylhydrazino-6-methyl-1-(2,6-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-pyridylhydrazino-6-methyl-1-(2,6-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-6-ethyl-1-phenyl-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-6-ethyl-1-phenyl-1,2-dihydro-1,3,5-triazin-2-one
4-ethylhydrazino-6-ethyl-1-phenyl-1,2-dihydro-1,3,5-triazin-2-one
4-propylhydrazino-6-ethyl-1-phenyl-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-6-ethyl-1-phenyl-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-6-ethyl-1-phenyl-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-6-ethyl-1-phenyl-1,2-dihydro-1,3,5-triazin-2-one
4-propargylhydrazino-6-ethyl-1-phenyl-1,2-dihydro-1,3,5-triazin-2-one
4-pyridylhydrazino-6-ethyl-1-phenyl-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-6-ethyl-1-(2-methylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-6-ethyl-1-(2-methylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-ethylhydrazino-6-ethyl-1-(2-methylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propylhydrazino-6-ethyl-1-(2-methylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-6-ethyl-1-(2-methylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-6-ethyl-1-(2-methylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-6-ethyl-1-(2-methylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propargylhydrazino-6-ethyl-1-(2-methylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-pyridylhydrazino-6-ethyl-1-(2-methylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-6-ethyl-1-(2-ethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-6-ethyl-1-(2-ethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-ethylhydrazino-6-ethyl-1-(2-ethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propylhydrazino-6-ethyl-1-(2-ethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-6-ethyl-1-(2-ethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-6-ethyl-1-(2-ethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-6-ethyl-1-(2-ethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propargylhydrazino-6-ethyl-1-(2-ethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-pyridylhydrazino-6-ethyl-1-(2-ethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-6-ethyl-1-(2-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-6-ethyl-1-(2-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-ethylhydrazino-6-ethyl-1-(2-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propylhydrazino-6-ethyl-1-(2-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-6-ethyl-1-(2-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-6-ethyl-1-(2-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-6-ethyl-1-(2-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propargylhydrazino-6-ethyl-1-(2-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-pyridylhydrazino-6-ethyl-1-(2-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-6-ethyl-1-(4-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-6-ethyl-1-(4-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-ethylhydrazino-6-ethyl-1-(4-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propylhydrazino-6-ethyl-1-(4-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-6-ethyl-1-(4-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-6-ethyl-1-(4-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-6-ethyl-1-(4-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propargylhydrazino-6-ethyl-1-(4-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-pyridylhydrazino-6-ethyl-1-(4-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-6-ethyl-1-(3,4-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-6-ethyl-1-(3,4-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-ethylhydrazino-6-ethyl-1-(3,4-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propylhydrazino-6-ethyl-1-(3,4-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-6-ethyl-1-(3,4-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-6-ethyl-1-(3,4-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-6-ethyl-1-(3,4-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propargylhydrazino-6-ethyl-1-(3,4-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-pyridylhydrazino-6-ethyl-1-(3,4-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propargylhydrazino-6-ethyl-1-phenyl-1,2-dihydro-1,3,5-triazin-2-one
4-pyridylhydrazino-6-ethyl-1-phenyl-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-6-ethyl-1-(3-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-6-ethyl-1-(3-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-ethylhydrazino-6-ethyl-1-(3-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propylhydrazino-6-ethyl-1-(3-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-6-ethyl-1-(3-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-6-ethyl-1-(3-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-6-ethyl-1-(3-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propargylhydrazino-6-ethyl-1-(3-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-pyridylhydrazino-6-ethyl-1-(3-chlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-6-ethyl-1-(3,4-ditrifluoroacetoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-6-ethyl-1-(3,4-ditrifluoroacetoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-ethylhydrazino-6-ethyl-1-(3,4-ditrifluoroacetoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propylhydrazino-6-ethyl-1-(3,4-ditrifluoroacetoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-6-ethyl-1-(3,4-ditrifluoroacetoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-6-ethyl-1-(3,4-ditrifluoroacetoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-6-ethyl-1-(3,4-ditrifluoroacetoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propargylhydrazino-6-ethyl-1-(3,4-ditrifluoroacetoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-pyridylhydrazino-6-ethyl-1-(3,4-ditrifluoroacetoxyphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-6-ethyl-1-(2,6-dimethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-6-ethyl-1-(2,6-dimethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-ethylhydrazino-6-ethyl-1-(2,6-dimethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propylhydrazino-6-ethyl-1-(2,6-dimethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-6-ethyl-1-(2,6-dimethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-6-ethyl-1-(2,6-dimethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-6-ethyl-1-(2,6-dimethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propargylhydrazino-6-ethyl-1-(2,6-dimethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-pyridylhydrazino-6-ethyl-1-(2,6-dimethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-6-ethyl-1-(2,6-diethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-6-ethyl-1-(2,6-diethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-ethylhydrazino-6-ethyl-1-(2,6-diethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propylhydrazino-6-ethyl-1-(2,6-diethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-6-ethyl-1-(2,6-diethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-6-ethyl-1-(2,6-diethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-6-ethyl-1-(2,6-diethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propargylhydrazino-6-ethyl-1-(2,6-diethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-pyridylhydrazino-6-ethyl-1-(2,6-diethylphenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-hydrazino-6-ethyl-1-(2,6-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-methylhydrazino-6-ethyl-1-(2,6-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-ethylhydrazino-6-ethyl-1-(2,6-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propylhydrazino-6-ethyl-1-(2,6-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-phenylhydrazino-6-ethyl-1-(2,6-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-benzylhydrazino-6-ethyl-1-(2,6-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-allylhydrazino-6-ethyl-1-(2,6-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-propargylhydrazino-6-ethyl-1-(2,6-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
4-pyridylhydrazino-6-ethyl-1-(2,6-dichlorophenyl)-1,2-dihydro-1,3,5-triazin-2-one
The hydrazinyl compounds which possess blood pressure-lowering activity can be used as antihypertensive agents by oral, parenteral or rectal administration. Orally they may be administered as tablets, aqueous or oily suspensions, dispersible powders or granules, emulsions, hard or soft capsules, or syrups or elixers. Parenterally they may be administered as a salt in solution which pH is adjusted to physiologically accepted values. Aqueous solutions are preferred.
Compositions intended for oral use may be prepared according to any method known to the art for the manufacture of pharmaceutical compositions, and such compositions may contain one or more inert carrier agents including excipients, such as, sweetening agents, flavoring agents, coloring agents, preserving agents and the like, in order to provide a pharmaceutically elegant and palatable preparation.
The dosage regimen in carrying out the methods of this invention is that which ensures maximum therapeutic response until improvement is obtained, and thereafter the minimum effective level which gives relief. Thus, in general, the dosages are those that are therapeutically effective in the alleviation of hypertensive disorders. The therapeutically effective doses correspond to those dosage amounts found effective in tests using animal models which are known to correlate to human activity. In general, it is expected that daily doses between about 5 mg/kg and about 300 mg/kg (preferably in the range of about 10 to about 50 mg/kg/day), will be sufficient to produce the desired therapeutic effect, bearing in mind, of course, that in selecting the appropriate dosage in any specific case, consideration must be given to the patient's weight, general health, age, the severity of the disorder, and other factors which may influence response to the drug.
Various tests in animals have been carried out to show the ability of the compounds of this invention to exhibit reactions that can be correlated with activity in humans. These tests involve such factors as their blood pressure-lowering effect and determination of their toxicity. It has been found that the preferred compounds of this invention, when tested in the above situation, show a marked blood pressure-lowering activity.
Determination of Antihypertensive Activity
A description of the test protocol used in the determination of the antihypertensive activity of the compounds of this invention follows:
(a) Male TAC spontaneously hypertensive rats (SHR's), eleven weeks old, weighing 200-220 grams, are chosen for testing. The average systolic blood pressure (as measured below) should be 165 mmHg or above. Any rat not initially meeting this criterion is not utilized.
(b) A Beckman dynograph is balanced and calibrated using a Beckman indirect blood pressure coupler. A mercury monometer is placed on one arm of the glass "T" tube. The known pressure head in the tail cuff is synchronized with the recorder output so that 1 mm pen deflection=5 mmHg. Any correction is made using the chart calibration screw on the pressure coupler. The pulse amplitude is controlled by the pre-amplifier using a 20 v/cm setting.
The rats are prewarmed in groups of five for twenty minutes to dilate the tail artery from which the arterial pulse is recorded. After prewarming, each rat is placed in an individual restraining cage with continued warming. When the enclosure temperature has been maintained at 35° C. for 5 minutes, recordings are started. The tail cuff is placed on the rat's tail and the rubber bulb of the pneumatic tail cuff transducer is taped securely to the dorsal surface of the tail. When the rat's pulse reaches maximum amplitude and is unwavering, the cuff is inflated and the air slowly released. A reading of systolic blood pressure is read at the point of the chart when the first deflection appears on the chart recording while the air in the cuff is being released. The exact point of the systolic blood pressure reading is where the first deflection forms a 90° angle to the falling cuff pressure base line. After obtaining nine or ten consistent readings, the average of the middle five readings is calculated.
(c) Three groups of twenty rats receive the test compound at doses of about 25 mg/kg per os.
A fourth group of twenty control rats receive distilled water. Statistical comparisons of systolic pressure (four hours ater the first dose and sixteen hours after the second dose) are made on a daily basis using the Student t test for dependent variables (see, E. Lord, Biometrika, 34, 56 (1947)), with the predose observations serving as baseline values for each rat.
This testing method is known to correlate well with antihypertensive activity in humans and is a standard test used to determine antihypertensive properties. Accordingly, hydrazine triazinones which show effectiveness in the test can be considered to be active antihypertensive agents in humans. | ##STR1## This invention relates to 1-aryl-4-hydrazinyl-1,2-dihydro-1,3,5-triazin-2-ones and 2-thiones of Formula I, processes for their preparation, isobiuret and 4-alkoxy-s-triazinone preparative intermediates, and methods of treating physiological disorders in humans and animals, in particular, cardiovascular disorders, including hypertension. | 64,064 |
CROSS REFERENCE OF RELATED APPLICATIONS
[0001] Under 35 U.S.C. §119(e), this application claims priority of U.S. Provisional Patent Application Ser. No. 61/149,688 filed Feb. 3, 2009, entitled “LIGHTWEIGHT PINCH GRIP HANGER”, the disclosure of which is hereby incorporated by reference in its entirety for all purposes.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] The present invention relates generally to molded plastic garment hangers as are widely used for the purpose of shipping and displaying garments. More specifically, the present invention relates to a lightweight pinch grip hanger with improved hanger body and pinch grips, which consumes less material and less energy for processing the material as compared to the prior art pinch grip hangers, while enhancing the pinch grip strength of the hanger, and without compromising the structural integrity and mechanical performance of the hanger.
[0004] 2. Description of Related Art
[0005] In the area of retail garment sales, so-called Garment-On-Hanger (GOH) programs have become preferred by retailers. In a GOH program, garments are delivered to retail merchants already suspended from hangers, where upon arrival at the retail location the garments are immediately placed on display for sale. Those hangers are normally plastic molded hangers as widely used for the purpose of shipping and displaying garments.
[0006] In particular, different retailers have specified particular hangers or hanger characteristics among their several suppliers in order to achieve uniformity on their sales floors. To this end, industry standards as to hanger size, shape, performance characteristics, etc., are maintained, for example, by organizations such as the Voluntary Inter-industry Commerce Standards Association (VICS).
[0007] With the continuing consumption of the natural resources, it is popular and necessary in the manufacturing industry, especially for mass production, to optimize the product design to save materials and energy and concomitantly reduce the manufacturing and transportation costs, without compromising performance. The resultant product under such a material and energy saving concept is recognized as an environmentally friendly product, and is much more market competitive than its prior art counterpart. Specifically, in the plastic hanger molding industry, millions of plastic hangers are manufactured each year. Thus, a lightweight pinch grip hanger, which consumes less material and less energy for processing the material compared to the prior art pinch grip hangers, greatly reduces manufacturing and transportation costs of a large amount of the hangers. Accordingly, the lightweight pinch grip hanger is environmentally advantageous, and also provides a significant commercial advantage to the manufacturer, transporter and retailer in the industry.
[0008] It is desirable, however, that when a large amount of improved hangers, such as lightweight hangers, are transported and handled by the existing mechanical systems, these hangers do not conflict or interfere with the existing mechanical systems to adversely impact operability.
[0009] Accordingly, there is a need for a novel pinch grip hanger that employs less material in manufacturing, reduces transportation costs and enhances the pinch grip strength of the hanger, while maintaining its structural integrity and mechanical performance to satisfy current industry standards, for example, the VICS standards.
[0010] Accordingly, there is a need for a novel pinch grip hanger that is lightweight and easy to handle while enhancing the pinch grip strength and still maintaining the performance of the hanger.
[0011] Accordingly, there is a need for a novel pinch grip hanger that effectively reduces manufacturing and transportation costs of the hanger, and uses less material to protect the environment.
[0012] Accordingly, there is a need for a novel pinch grip hanger made from less material while enhancing the pinch grip strength and still maintaining performance and compatibility with the existing mechanical systems in the retailer facilities for transporting and handling hangers.
BRIEF SUMMARY OF THE INVENTION
[0013] Therefore, in order to overcome certain deficiencies of the prior art, provided according to the present invention is a lightweight pinch grip hanger. The pinch grip hanger includes a hook member and a body connected to the hook. The body includes a first arm extending from a centerline of the body to a first end of the body and a second arm extending from the centerline to a second end of the body. The hanger further includes a first pinch grip connected to the first end of the body, which includes a fixed jaw connected to the first end and a movable jaw mounted to the fixed jaw through a pivot shaft. The movable jaw includes an upper end which is moved toward an upper end of the fixed jaw when the movable jaw is actuated to open the pinch grip. The body further includes an upper flange, a lower flange and a connecting web between the upper flange and the lower flange. The first upper end of the movable jaw and the second upper end of the fixed jaw extend upwardly beyond the upper flange of the body.
[0014] Preferably, the hanger body further includes an elevated portion formed substantially in the middle of the hanger body.
[0015] Preferably, the pinch grip of the hanger is dimensioned to have a narrowed width relative to standard prior art pinch grip hangers.
[0016] Preferably, the upper flange and lower flange of the hanger body are substantially horizontal and parallel to each other and the connecting web is substantially vertical to the upper and lower flanges.
[0017] Preferably, the connecting web includes an upper straight portion, a lower straight portion, and a curved portion connecting the upper straight portion and the lower straight portion.
[0018] Preferably, the first pinch grip includes a spring for applying a biasing force, against which the upper end of the moveable jaw and the upper end of the fixed jaw are moved toward each other to open the pinch grip. More preferably, the spring includes a cutout.
[0019] Preferably, the hanger further includes a second pinch grip connected to the second end of the body. The second pinch grip includes a fixed jaw connected to the first end and a movable jaw mounted to the fixed jaw through a pivot shaft, the movable jaw comprising an upper end which is moved toward an upper end of the fixed jaw when the movable jaw is actuated to open the pinch grip.
[0020] Preferably, the hanger further includes a supporting web integrally molded with the hanger body and the first pinch grip. More preferably, the hanger includes a first supporting web integrally molded with the hanger body and the first pinch grip and a second supporting web integrally molded with the hanger body and the second pinch grip.
[0021] Preferably, the hanger body further includes a post extending upward from the body for receiving the hook member and a pair of reinforcing flanges disposed angularly between the post and the upper flange of the body. More preferably, the hanger further includes a size indicator operatively engaging the post and/or the reinforcing flanges to mount the indicator onto the hanger body, the size indicator capable of being actuated to release the engagement between the indicator and the hanger body. More preferably, the hanger further includes a size indicator operatively engaging the upper flange of the hanger body to mount the indicator onto the hanger body, the size indicator capable of being actuated to release the engagement between the indicator and the hanger body.
[0022] Provided according to another aspect of the present invention is a pinch grip hanger. The hanger includes a hook member, a body connected to the hook, and an elevated portion arranged between the hook member and the body. The body includes a first arm extending to a first end of the body and a second arm extending oppositely to a second end of the body. The body further includes an upper flange and a lower flange connected by a middle web, the middle web including an upper straight portion, a lower straight portion and a curved portion between the upper straight portion and the lower straight portion. The hanger further includes a first pinch grip, having a first fixed jaw integrally molded to the first end of the body, a first movable jaw mounted to the first fixed jaw through a first pivot shaft, and a first biasing member against which the first movable jaw is actuated to selectively open the first pinch grip. The first fixed jaw includes an upper end positioned vertically above the upper flange of the body and the first moveable jaw includes an upper end positioned vertically above the upper flange of the body. The hanger further includes a second pinch grip, having a second fixed jaw integrally molded to the second end of the body, a second movable jaw mounted to the second fixed jaw through a second pivot shaft, and a second biasing member against which the second movable jaw is actuated to selectively open the second pinch grip. The second fixed jaw includes an upper end positioned vertically above the upper flange of the body and the second moveable jaw includes an upper end positioned vertically above the upper flange of the body.
[0023] Provided according to another aspect of the present invention is a combination of hanger and size indicator. The combination includes a hanger and a size indicator. The hanger includes a hook member, a body connected to the hook, and a first pinch grip connected to the body. The body includes a first arm extending from a centerline of the body to a first end of the body and a second arm extending from the centerline to a second end of the body. The first pinch grip includes a fixed jaw connected to the first end and a movable jaw mounted to the fixed jaw through a pivot shaft. The movable jaw includes an upper end which is moved toward an upper end of the fixed jaw when the movable jaw is actuated to open the pinch grip. The body further includes an upper flange, a lower flange and a connecting web between the upper flange and the lower flange, and the upper end of the movable jaw and the upper end of the fixed jaw extend upwardly beyond the upper flange of the body. The body further includes a post extending upward from the body for receiving the hook member and a pair of reinforcing flanges disposed angularly between the post and the upper flange of the body. The size indicator operatively engages at least one of the post, the reinforcing flanges and the upper flange of the body, to mount the indicator onto the hanger body. The size indicator is capable of being actuated to release the engagement between the indicator and the hanger body.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] These and other features, aspects and benefits of the present invention will be made apparent with reference to the following specification and accompanying drawings, where like reference numerals refer to like features across the several views, and wherein:
[0025] FIG. 1 is a prior art pinch grip hanger;
[0026] FIG. 2 is a cross section view along line 2 - 2 in FIG. 1 , showing M section configuration of the prior art pinch grip hanger;
[0027] FIG. 3 is an enlarged view of the prior art pinch grip hanger taken along the phantom line in FIG. 1 , showing the details of a pinch grip of the hanger;
[0028] FIG. 4 is a front view showing a pinch grip hanger according to an exemplary embodiment of the present invention;
[0029] FIG. 5 is a cross section view along line A-A in FIG. 4 , showing an I-beam section of the pinch grip hanger;
[0030] FIG. 6 is a front view showing a pinch grip hanger according to another exemplary embodiment of the present invention;
[0031] FIG. 6A is an enlarged view of a portion of the hanger in FIG. 6 ;
[0032] FIG. 7 is a front view showing a pinch grip hanger according to another exemplary embodiment of the present invention;
[0033] FIG. 8 is a front view showing a pinch grip hanger according to another exemplary embodiment of the present invention; and
[0034] FIG. 9 is a cross section view along line B-B in FIG. 8 , showing a curved beam of the pinch grip hanger.
DETAILED DESCRIPTION OF THE INVENTION
[0035] Referring to FIG. 1 , illustrated is a pinch grip hanger 100 as is known in the art. The hanger has a hook member 110 and a hanger body 120 connected to the hook member 110 substantially at the middle of the body 120 . The hanger body 120 is substantially symmetrical along a centerline CL of the body, as shown in the figure.
[0036] The body 120 has an upper portion, which includes a centrally located boss 130 , to which the hook member 110 is rotatably mounted. The boss 130 is reinforced by a pair of flanges 132 and 134 on opposite sides thereof, which are integrally molded and joined to a the body 120 . Preferably, the pair of flanges 132 and 134 are substantially symmetrical to one another relative to the centerline CL of the hanger body 120 .
[0037] The region of the hanger, where the boss 130 and the flanges 132 and 134 are disposed and where the hook member 110 joins the hanger body 120 , is normally identified as a lower neck region of the hanger. The lower neck region can be used to attach an indicator for displaying information indicia with respect to the size, color and so on of the garments.
[0038] The hook member 110 is preferably fabricated from wire stock and is connected to the hanger by insertion into the boss 130 . The removal of the metal hook member is prevented by any conventional attachment such as a threaded connection or an anchor clip.
[0039] The hanger body 120 includes a first arm 140 extending from the centerline CL of the body 120 to a first end 142 of the body and a second arm 150 extending from the centerline CL of the body 120 to a second end 152 of the body. The first arm 140 and the second arm 150 are geometrically symmetrical to one another relative to the centerline CL and are integrally molded to provide a single piece hanger beam. The hanger 100 further includes a first pinch grip 160 integrally molded to the first end 142 and a second pinch grip 180 integrally molded to the second end 152 . The pinch grips can be actuated by a user to switch from a closed configuration to an open configuration for selectively holding a portion of a garment, which will be described later with reference to FIG. 3 .
[0040] Referring to FIG. 2 , illustrated is a cross section view of the body 120 . The body 120 includes an upper flange 144 , a lower flange 146 and a web 148 for connecting the upper flange 144 and the lower flange 146 . The upper flange 144 and the lower flange 146 are substantially horizontal and parallel to one another. The web 148 connects the upper flange 144 and the lower flange 146 , thus to provide an M section configuration of the body 120 .
[0041] Referring to FIG. 3 , illustrated is an enlarged view of the hanger 100 in the phantom line of FIG. 1 , showing the details of the pinch grip 160 and conjunction of the first pinch grip 160 with the hanger body 120 .
[0042] The first pinch grip 160 includes a fixed jaw 162 integrally molded to the first end 142 of the hanger body 120 , a movable jaw 164 mounted to the fixed jaw 162 through a pivot shaft 166 . The movable jaw 164 includes an actuating portion 168 formed at the upper end 170 of the movable jaw 164 . The actuating portion 168 can be engaged by a user's finger to pivotally move the movable jaw 164 relative to the fixed jaw 162 around the pivot shaft 166 , against the biasing force applied by a spring 172 operatively mounted to the first pinch grip 160 . With the movement of the movable jaw 164 , the upper end 170 of the movable jaw 164 approaches the upper end 174 of the fixed jaw 162 , while the lower end 176 of the movable jaw 164 moves away from the lower end 178 of the fixed jaw 162 . Accordingly, the first pinch grip 160 switches from its closed configuration to its open configuration, to selectively hold a portion of a garment.
[0043] As shown in FIG. 3 , the first pinch grip 160 has a first width W 1 , defined substantially from the left most point of the first pinch grip 160 to the right most point of the pinch grip 160 , and a first height H 1 , defined substantially from the upper most surface of the upper ends 170 and 174 to the lower most surface of the lower ends 176 and 178 . The hanger body 120 has a second height H 2 , defined substantially from the upper flange 144 to the lower flange 146 of the body 120 .
[0044] Furthermore, the first pinch grip 160 is joined to the first end 142 of the hanger body 120 in such a manner that the upper end 170 of the movable jaw 164 and the upper end 174 of the fixed jaw 162 are in flush with the upper flange 144 of the hanger body 120 . In other words, the upper most surface of the upper end 170 , the upper most surface of the upper end 174 , and the surface of the upper flange 144 are substantially in a same horizontal plane.
[0045] The configuration of the second pinch grip 180 is correspondingly similar.
[0046] Referring again to FIG. 1 , the height of the hanger, from the upper most point of the hook member 110 to the lower flange 146 of the hanger body 120 , is shown as H A .
[0047] Referring to FIG. 4 , illustrated is a lightweight pinch grip hanger according to an exemplary embodiment of the present invention, identified by numeral 200 . The hanger 200 includes a hook 220 and a body 240 connected to the hook 220 . Preferably, the body 240 is substantially symmetrical to a vertical centerline CL 1 of the hanger.
[0048] The hanger 200 further includes a post 250 extending upward from the body 240 , the intersection of the post 250 and the body 240 defining a lower neck region of the hanger, where a lower neck sizer may be attached. The hook 220 is mounted to the post 250 through any known implement, such as mating threads. An example of the lower neck sizer can be found at U.S. Pat. No. 7,513,400 under the title “Spring Top Lower Neck Hanger Sizing” or U.S. Pat. No. 7,516,875 under the title “Lower Neck Indicator for Wire Hook Hanger”, which are commonly owned by the applicant of the present application. The entire disclosures of the above patents are incorporated by reference for all purposes.
[0049] The hanger 200 further includes a pair of flanges 270 and 272 , disposed angularly between the post 250 and the body 240 , for reinforcing the post 250 . The reinforcing flanges 270 and 272 are disposed on opposite sides of the post 250 and are integrally molded to the body 240 and the post 250 . Preferably, the pair of flanges 270 and 272 substantially symmetrical to one another relative to the centerline CL 1 of the hanger body 240 . For example, the lower neck sizer operatively engages the post 250 and/or the flanges 270 and 272 , to mount the sizer onto the hanger. Alternatively, the lower neck sizer may engage an upper flange of the hanger body, which will be described later. Preferably, the indicator can be actuated to selectively release the engagement between the sizer and the hanger.
[0050] The hanger body 240 includes a first arm 242 extending from the centerline CL 1 to a first end 244 of the hanger body 240 and a second arm 246 extending oppositely from the centerline CL 1 to a second end 248 of the hanger body 240 .
[0051] Preferably, the first arm 242 and the second arm 246 are geometrically symmetrical to one another relative to the centerline CL 1 to provide a unitary single-piece hanger beam. A first pinch grip 280 is integrally molded to the first end 244 and a second pinch grip 290 is integrally molded to the second end 248 . Preferably, the pinch grips 280 and 290 can be actuated by a user or a machine to switch from a closed configuration to an open configuration for selectively holding at least a portion of a garment.
[0052] FIG. 5 is a cross section view of the hanger body 240 . The body 240 includes an upper flange 241 , a lower flange 243 , and a connecting web 245 between the upper flange 241 and the lower flange 243 . Preferably, the upper flange 241 and the lower flange 243 are substantially horizontal and parallel to one another, and the connecting web 245 is substantially perpendicular to the upper flange 241 and the lower flange 243 . Accordingly, the hanger beam is substantially an I-beam. Alternatively, the web 245 can assume any other suitable shape, profile or position to provide an appropriate beam configuration for the hanger, such as a C-section beam.
[0053] Referring back to FIG. 4 , the first pinch grip 280 includes a fixed jaw 282 integrally molded to the first end 244 of the first arm 242 , a movable jaw 283 mounted to the fixed jaw 282 through a pivot shaft 284 . The movable jaw 283 includes an actuating portion 285 formed at the upper end 286 of the movable jaw 283 . The actuating portion 285 can be engaged by a user's finger to pivotally move the movable jaw 283 relative to the fixed jaw 282 around the pivot shaft 284 , against the biasing force applied by a spring 288 operatively mounted to the first pinch grip 280 .
[0054] With the movement of the movable jaw 283 , the upper end 286 of the movable jaw approaches the upper end 287 of the fixed jaw 282 , while the lower end of the movable jaw 283 moves away from the lower end of the fixed jaw 282 . Accordingly, the first pinch grip 280 switches from its closed configuration to its open configuration, to selectively hold a portion of a garment.
[0055] Preferably, the lower end of the movable jaw 283 and the lower end of the fixed jaw 282 are formed with a plurality of teeth for enhancing the pinching and gripping capacity of the grip. Other gripping configurations known in the art including a long jaw with a single elongated tooth or a padded surface are also contemplated.
[0056] Now referring to FIG. 5 , the hanger body 240 has a third height H 3 , defined substantially from the top of the upper flange 241 to the bottom of the lower flange 243 of the hanger body 240 . The third height H 3 is smaller than the second height H 2 of the standard prior art hanger 100 . Consequently, the resin material used for molding the hanger body 240 is reduced, compared to the prior art hanger 100 . Preferably, the ratio of the third height H 3 to the second height H 2 is approximately in the range of 40-90%. Accordingly, 10-60% less resin material is used for molding the hanger body 240 as compared to the material used for molding the hanger body 120 of the prior art hanger 100 .
[0057] The upper end 286 of the movable jaw 283 and the upper end 287 of the fixed jaw 282 extend upwardly beyond the upper flange 241 of the hanger body 240 . In other words, either the upper end 286 or the upper end 287 is positioned substantially in a horizontal plane vertically above the horizontal plane in which the upper flange 241 resides.
[0058] Furthermore, the inventor of the present invention has discovered that in such a configuration wherein the upper end 286 of the movable jaw 283 and the upper end 287 of the fixed jaw 282 extend upwardly beyond the upper flange 241 of the hanger body 240 , the leverage offered by the pinch grip is greater as compared to the prior art hanger 100 wherein the upper ends of the jaws of the pinch grip are flush with the upper flange of the hanger body. Accordingly, it is much more convenient for a user to operate the pinch grips of the hanger. The second pinch grip 290 is preferably structurally symmetrical to the first pinch grip 280 . In this regard, the pinch grip hanger 200 consumes less material by having a narrowed hanger beam, as well as shows a better performance for a user to operate the pinch grips.
[0059] In addition, the pinch grips 280 and 290 , according to the embodiment of the present invention, are narrowed, having a narrowed width compared to the pinch grips of the standard prior art hanger, in order to further enhance the gripping capacity of the pinch grips. In this way, the same biasing force applied by the same spring is distributed along a shorter distance at the lower ends of fixed jaw and the moveable jaw, compared to the known pinch grips having a greater width. Thus, the unit gripping force of the fixed jaw and the moveable jaw of the present invention is higher than that of the prior art hanger. Accordingly, a further advantage, that the garments are reliably gripped by the pinch grips, can be provided.
[0060] Specifically, as shown in FIG. 4 , taking the first pinch grip 280 as an example, the first pinch grip 280 has a second width W 2 , defined substantially from the left most point of the first pinch grip to the right most point of the first pinch grip. The second width W 2 is considerably smaller than the first width W 1 of the prior art hanger. Therefore, further material savings can be achieved by the slimmed pinch clip 280 , without compromising the mechanical performance of the hanger, in fact, enhancing the gripping capacity of the pinch grip.
[0061] FIG. 6 illustrates a pinch grip hanger 300 according to another exemplary embodiment of the present invention. The hanger 300 includes a hook 320 and a body 340 connected to the hook 320 . Preferably, the body 340 is substantially symmetrical to a vertical centerline CL 2 of the hanger.
[0062] The hanger 300 further includes a post 350 extending upward from the body 340 , the intersection of the post 350 and the body 340 defining a lower neck region of the hanger, where a lower neck sizer may be attached. The hook 320 is mounted to the post 350 through any known implement, such as mating threads.
[0063] The hanger 300 further includes a pair of flanges 370 and 372 , disposed angularly between the post 350 and the body 340 , for reinforcing the post 350 . The reinforcing flanges 370 and 372 are disposed on opposite sides of the post 350 and are integrally molded to the body 340 and the post 350 . Preferably, the pair of flanges 370 and 372 are substantially symmetrical to one another relative to the centerline CL 2 of the hanger body 340 .
[0064] The hanger body 340 includes a first arm 342 extending from the centerline CL 2 to a first end 344 of the hanger body 340 and a second arm 346 extending oppositely from the centerline CL 2 to a second end 348 of the hanger body 340 . Preferably, the first arm 342 and the second arm 346 are geometrically symmetrical to one another relative to the centerline CL 2 to provide a unitary single-piece hanger beam. A first pinch grip 360 is integrally molded to the first end 344 and a second pinch grip 380 is integrally molded to the second end 348 .
[0065] The body 340 includes an upper flange 341 , a lower flange 343 , and a connecting web 345 between the upper flange 341 and the lower flange 343 . Preferably, the upper flange 341 and the lower flange 343 are substantially horizontal and parallel to one another, and the connecting web 345 is substantially perpendicular to the upper flange 341 and the lower flange 343 . Accordingly, the hanger beam is substantially an I-beam. Alternatively, the web 345 can assume any other suitable shape, profile or position to provide an appropriate beam configuration for the hanger, such as a C-section beam.
[0066] The first pinch grip 360 includes a fixed jaw 362 integrally molded to the first end 344 of the first arm 342 , a movable jaw 363 mounted to the fixed jaw 362 through a pivot shaft 364 . The movable jaw 363 includes an actuating portion 365 formed at the upper end 366 of the movable jaw 363 . The actuating portion 365 can be engaged by a user's finger to pivotally move the movable jaw 363 relative to the fixed jaw 362 around the pivot shaft 364 , against the biasing force applied by a spring 368 operatively mounted to the first pinch grip 360 .
[0067] With the movement of the movable jaw 363 , the upper end 366 of the movable jaw approaches the upper end 367 of the fixed jaw 362 , while the lower end of the movable jaw 363 moves away from the lower end of the fixed jaw 362 . Accordingly, the first pinch grip 360 switches from its closed configuration to its open configuration, to selectively hold at least a portion of a garment. Similar to the hanger body 240 of the previous embodiment, the hanger body 340 has a same height H 3 defined from the upper flange of the hanger body to the lower flange of the hanger body.
[0068] Similarly, the second pinch grip 380 includes a fixed jaw 382 integrally molded to the second end 348 of the second arm 346 , a movable jaw 383 mounted to the fixed jaw 382 through a pivot shaft 384 . The movable jaw 383 includes an actuating portion 385 formed at the upper end 386 of the movable jaw 383 . The actuating portion 385 can be engaged by a user's finger to pivotally move the movable jaw 383 relative to the fixed jaw 382 around the pivot shaft 384 , against the biasing force applied by a spring 388 operatively mounted to the first pinch grip 380 .
[0069] The hanger 300 further includes an elevated portion 390 continuous to the hanger body 340 , under the post 350 and the support flanges 370 and 372 . The elevation portion 390 is formed to implement a seamless interchangeability between the hangers according to the present invention and the prior art hangers. Thus, for existing mechanical systems in the retailer's facility for transporting and handling garments and hangers, such as suspension bars, racks and conveyers, the prior art hangers can be replaced by the hangers of the present invention, without causing any problem regarding the compatibility of the hangers with the conventional mechanical systems. Specifically, the distance between the suspension bar and the hanger body can be maintained.
[0070] The elevated portion 390 includes an upper flange 392 and a pair of side flanges 394 and 396 . The pair of side flanges 394 and 396 are integrally molded to the upper flange 391 to provide a substantially trapezoidal or plateau shape of the elevated portion 390 with a continuous contour. Furthermore, the side flanges 394 and 396 are molded continuously and integrally with the upper flange of the hanger body 340 , and the elevation portion 390 is integrally molded with the hanger body 340 through a single molding process. Preferably, the elevated portion 390 is substantially symmetrical relative to the centerline CL 2 of the hanger body 340 . In the shown embodiment, the elevated portion 390 is substantially trapezoidal. However, it should be understood by a person of ordinary skill in the art that the elevated portion 390 can be of any suitable profile and shape.
[0071] Referring to FIG. 6A , the elevated portion 390 has a fourth height H 4 defined substantially from the upper flange 392 of the elevated portion 390 to the upper flange of the hanger body 340 . Compared to the embodiment shown in FIGS. 4 and 5 , the elevation portion 390 of the hanger 300 vertically raises the hanger hook 310 and the post 350 .
[0072] Thus, although the height H 3 of the hanger body 340 is smaller than the height H 2 of the hanger body 120 of the prior art hanger, the overall height H B of the hanger 300 , defined from the hook 320 to the lower flange of the hanger body 340 , is maintained substantially the same as the height H A of the prior art hanger 100 .
[0073] Accordingly, the hangers of the present invention can be readily interchanged with the prior art hangers in a retailer's facility, to accommodate the existing garment/hanger conveying systems used in a Garment-On-Hanger system.
[0074] Moreover, the height and the profile of the elevation portion 390 can be strategically adjusted, in association with the hook 310 , to further reduce the overall weight of the garment hanger 300 .
[0075] For example, the height H 4 of the elevation portion 390 can be further extended, and the hook 310 can be shortened and minimized correspondingly. The extended height of elevation portion 390 compensates for the shortening of the hook 310 , which additionally reduces the overall weight of the hanger, while still maintaining the overall height of the hanger for the purpose of accommodating conventional hanger/garment conveying systems in the retailer's facility.
[0076] FIG. 7 illustrates a pinch grip hanger 400 according to another exemplary embodiment of the present invention. The hanger 400 includes a hook 420 and a body 440 connected to the hook 420 . Preferably, the body 440 is substantially symmetrical to a vertical centerline CL 3 of the hanger.
[0077] The hanger 400 further includes a post 450 extending upward from the body 440 , the intersection of the post 450 and the body 440 defining a lower neck region of the hanger, where a lower neck sizer may be attached. The hook 420 is mounted to the post 450 through any known implement, such as mating threads.
[0078] The hanger 400 further includes a pair of flanges 470 and 472 , disposed angularly between the post 450 and the body 440 , for reinforcing the post 450 . The reinforcing flanges 470 and 472 are disposed on opposite sides of the post 450 and are integrally molded to the body 440 and the post 450 . Preferably, the pair of flanges 470 and 472 are substantially symmetrical to one another relative to the centerline CL 3 of the hanger body 440 .
[0079] The hanger body 440 includes a first arm 442 extending from the centerline CL 3 to a first end 444 of the hanger body 440 and a second arm 446 extending oppositely from the centerline CL 3 to a second end 448 of the hanger body 440 . Preferably, the first arm 442 and the second arm 446 are geometrically symmetrical to one another relative to the centerline CL 3 to provide a unitary single-piece hanger beam. A first pinch grip 460 is integrally molded to the first end 444 and a second pinch grip 480 is integrally molded to the second end 448 .
[0080] The body 440 includes an upper flange 441 , a lower flange 443 , and a connecting web 445 between the upper flange 441 and the lower flange 443 . Preferably, the upper flange 441 and the lower flange 443 are substantially horizontal and parallel to one another, and the connecting web 445 is substantially perpendicular to the upper flange 441 and the lower flange 443 . Accordingly, the hanger beam is substantially an I-beam. Alternatively, the web 445 can assume any other suitable shape, profile or position to provide an appropriate beam configuration for the hanger, such as a C-section beam.
[0081] The first pinch grip 460 includes a fixed jaw 462 integrally molded to the first end 444 of the first arm 442 , a movable jaw 463 mounted to the fixed jaw 462 through a pivot shaft 464 . The movable jaw 463 includes an actuating portion 465 formed at the upper end 466 of the movable jaw 463 . The actuating portion 465 can be engaged by a user's finger to pivotally move the movable jaw 463 relative to the fixed jaw 462 around the pivot shaft 464 , against the biasing force applied by a spring 468 operatively mounted to the first pinch grip 460 .
[0082] With the movement of the movable jaw 463 , the upper end 466 of the movable jaw approaches the upper end 467 of the fixed jaw 462 , while the lower end of the movable jaw 463 moves away from the lower end of the fixed jaw 462 . Accordingly, the first pinch grip 460 switches from its closed configuration to its open configuration, to selectively hold at least a portion of a garment. Similar to the hanger body 240 of the previous embodiment, the hanger body 440 has a same height H 3 defined from the upper flange of the hanger body to the lower flange of the hanger body.
[0083] Similarly, the second pinch grip 480 includes a fixed jaw 482 integrally molded to the second end 448 of the second arm 446 , a movable jaw 483 mounted to the fixed jaw 482 through a pivot shaft 484 . The movable jaw 483 includes an actuating portion 485 formed at the upper end 486 of the movable jaw 483 . The actuating portion 485 can be engaged by a user's finger to pivotally move the movable jaw 483 relative to the fixed jaw 482 around the pivot shaft 484 , against the biasing force applied by a spring 488 operatively mounted to the first pinch grip 480 .
[0084] In the embodiment, the hanger 400 further includes a pair of supporting webs 920 and 940 , positioned between the first end 444 and the fixed jaw 462 of the first pinch grip 460 and between the second end 448 and the fixed jaw 482 of the second pinch grip 480 , respectively. The supporting webs 920 and 940 structurally expand between the ends of the hanger body and the pinch grips. Specifically, the first supporting web 920 structurally connects the undersurface of the lower flange 443 , at the first end 444 , to the right lateral side of the fixed jaw 462 ; and the second supporting web 940 structurally connects the undersurface of the lower flange 443 , at the second end 448 , to the left lateral side of the fixed jaw 482 . Preferably, the supporting web 920 is integrally molded to the fixed jaw 462 of the first pinch grip 460 and the first end 444 of the hanger body 440 , and the supporting web 940 is integrally molded to the fixed jaw 482 of the second pinch grip 480 and the second end 448 of the hanger body 440 .
[0085] The provision of the supporting webs effectively enhances the physical connection between the hanger beam and the pinch grips as well as the overall strength and integrity of the hanger body. Accordingly, the undesirable breaking off of the pinch grip is further prevented.
[0086] In the shown embodiment, both supporting webs 920 and 940 are a thin layer of plastic material in the shape of substantial triangle with a curved underside. However, a person of ordinary skill in the art should appreciate that any other suitable shape and profile can be applied in place of or in addition to the shown structure.
[0087] Furthermore, in the shown embodiment, the supporting webs 920 and 940 are both disposed under the lower flange 443 of the hanger body 440 , connecting the underside of the hanger body 440 with a lateral side of the fixed jaws of the pinch grips. Alternatively, the supporting webs 920 and 940 can be formed on the on the upper flange 441 of the hanger body 440 , connecting the upside of the hanger body 440 with a lateral side of the fixed jaws of the pinch grips.
[0088] The hanger 400 further includes an elevated portion 490 continuous to the hanger body 440 , under the post 450 and the support flanges 470 and 472 . The elevation portion 490 is formed to implement a seamless interchangeability between the hangers according to the present invention and the prior art hangers. Thus, for existing mechanical systems in the retailer's facility for transporting and handling garments and hangers, such as suspension bars, racks and conveyers, the prior art hangers can be replaced by the hangers of the present invention, without causing any problem regarding the compatibility of the hangers with the conventional mechanical systems. Specifically, the distance between the suspension bar and the hanger body can be maintained.
[0089] FIG. 8 illustrates a pinch grip hanger 500 according to another exemplary embodiment of the present invention. The hanger 500 includes a hook 520 and a body 540 connected to the hook 520 . Preferably, the body 540 is substantially symmetrical to a vertical centerline CL 4 of the hanger.
[0090] The hanger 500 further includes a post 550 extending upward from the body 540 , the intersection of the post 550 and the body 540 defining a lower neck region of the hanger, where a lower neck sizer may be attached. The hook 520 is mounted to the post 550 through any known implement, such as mating threads.
[0091] The hanger 500 further includes a pair of flanges 570 and 572 , disposed angularly between the post 550 and the body 540 , for reinforcing the post 550 . The reinforcing flanges 570 and 572 are disposed on opposite sides of the post 550 and are integrally molded to the body 540 and the post 550 . Preferably, the pair of flanges 570 and 572 substantially symmetrical to one another relative to the centerline CL 4 of the hanger body 540 .
[0092] The hanger body 540 includes a first arm 542 extending from the centerline CL 4 to a first end 544 of the hanger body 540 and a second arm 546 extending oppositely from the centerline CL 4 to a second end 548 of the hanger body 540 . Preferably, the first arm 542 and the second arm 546 are geometrically symmetrical to one another relative to the centerline CL 4 to provide a unitary single-piece hanger beam.
[0093] The hanger 500 includes a first pinch grip 560 connected to the first end 544 and a second pinch grip 580 integrally molded to the second end 548 . The first pinch grip 560 includes a fixed jaw 562 integrally molded to the first end 544 of the first arm 542 and a movable jaw 563 mounted to the fixed jaw 562 through a pivot shaft 564 . The movable jaw 563 includes an actuating portion 565 formed at the upper end 566 of the movable jaw 563 . The actuating portion 565 can be engaged by a user's finger to pivotally move the movable jaw 563 relative to the fixed jaw 562 around the pivot shaft 564 , against the biasing force applied by a spring 568 operatively mounted to the first pinch grip 560 .
[0094] With the movement of the movable jaw 563 , the upper end 566 of the movable jaw approaches the upper end 567 of the fixed jaw 562 , while the lower end of the movable jaw 563 moves away from the lower end of the fixed jaw 562 . Accordingly, the first pinch grip 560 switches from its closed configuration to its open configuration, to selectively hold at least a portion of a garment. The second pinch grip 580 has same or similar structures.
[0095] The hanger 500 further includes an elevated portion 590 continuous to the hanger body 540 , under the post 550 and the support flanges 570 and 572 . The elevation portion 590 is similar to the elevation portion 390 of the hanger 300 .
[0096] FIG. 9 is a cross section view of the hanger body 540 , along the sectional lines B-B in FIG. 8 . The body 540 includes an upper flange 541 , a lower flange 543 , and a connecting web 545 between the upper flange 541 and the lower flange 543 .
[0097] Preferably, the upper flange 541 and the lower flange 543 are substantially horizontal and parallel to one another. In this exemplary embodiment, the connecting web 545 includes an upper straight portion 546 , a lower straight portion 547 and a middle curved portion 548 between the upper straight portion 546 and the lower straight portion 547 . Accordingly, viewed from the side, the hanger beam has a raised membrane from the plane of the vertical part of the hanger beam, as shown in FIG. 9 . The rippled configuration of the hanger beam significantly improves the rigidity of the hanger beam. Preferably, the curved portion 548 extends through the overall length of the hanger body 540 .
[0098] Although only one curved portion 448 is shown in the figure, it should be understood by a person of ordinary skill in the art that a plurality of curved portions can be formed, raising from either side of the hanger beam.
[0099] Similar to the hanger body 240 and 340 of the previous embodiments, the hanger body 540 has a same height H 3 defined from the upper flange 541 of the hanger body 540 to the lower flange 543 of the hanger body 540 , such that the hanger 500 can readily replace a prior art hanger in a Garment-On-Hanger system, without causing any conflict or interference with the existing bars, racks and conveyers of the retailer's facility.
[0100] The inventor of the present invention has conducted a comparison experiment for assessing the resin material saved by an example of the novel configuration of the pinch grip hanger according to the present invention.
[0101] Following Table 1 presents the comparison of the parameters of the hanger according to the present invention vis-à-vis the parameters of a market-accessible prior art hanger (such as a “6012/12” pinch grip hanger according to VICS), both hangers meeting the requirements of the acknowledged industry standards, such as the VICS standards.
[0000]
TABLE 1
Prior Art
Pinch Grip
Pinch Grip Hanger of the
Hanger (having
Present Invention (having
Parameters
an I beam)
an I beam)
Height of I beam
0.75″
0.50″
Width of I beam
0.30″
0.30″
Height/width ratio of I beam
2.5
1.67
Weight of metal hook
8.0
g
8.0
g
Weight of metal springs
5.0
g
5.0
g
Weight of K resin of hanger
23.6
g
20.0
g
body
Weight of K resin of clips
7.5
g
6.2
g
Total weight of K resin of
31.1
g
26.2
g
hanger
Total weight of hanger
44.1
g
39.2
g
[0102] It can be concluded from the Table 1 that, compared to the prior art hanger averagely consuming 31.1 g of K resin, the hanger according to the present invention consumes 26.2 g of K resin. In other words, 4.9 g of K resin are saved per hanger, which accounts for about 15.75% of the total resin material of the prior art hanger. With significantly less resin material consumed, the mechanical performances of the hanger according to the present invention are still maintained at a level same or even superior than that of the prior art hanger.
[0103] Each year, about 750 million pinch grip hangers are manufactured in accordance with the VICS standards. Thus, the pinch grip hanger according to the present invention would reduce the K resin material by about 8.1 million pounds annually, which would eliminate about 24.0 million pounds of CO 2 emission for producing the same amount of K resin. Furthermore, the reduction of resin material leads to less consumption of energy and resources for storing, transporting and handling the hangers. Hence, the pinch grip hanger according to the present invention helps to preserve environment and resources, while still providing improved products to the consumers.
[0104] The hanger of the present invention can be formed of one or more of polystyrene, SAN, ABS, PPO, nylon, polypropylene (PP), polyethylene, PET, polycarbonates (PC), acrylics, K-resin, and polyvinyl chloride (PVC) among others.
[0105] From the foregoing illustrations it is readily apparent that the present invention is directed to a lightweight molded plastic garment hanger for high volume injection molding. According to the shown embodiments of the present invention, the resin material for molding the hanger body can be significantly reduced, and concomitantly the manufacturing cost and transportation cost of the hangers can be significantly reduced, while maintaining the strength, integrity and performance of the hanger. Consequently, the pinch grip hanger according to the present invention can offer the manufacturers, transporters and retailers of the hangers a market advantage, which cannot be offered by the traditional pinch grip hanger.
[0106] The hangers of the present invention consume less material while still maintaining the mechanical performance under industry standards, for example, the VICS standards. Moreover, the production of such hangers is environmentally advantageous.
[0107] The present invention has been described with respect to certain exemplary embodiments. Certain alterations and/or modifications will be apparent to those skilled in the art, in light of the instant disclosure, without departing from the spirit or the scope of the invention. These embodiments are offered as merely illustrative, and not limiting, on the scope of the invention, which is defined solely with reference to the following appended claims. | In a lightweight and environmentally friendly pinch grip hanger, the height of the hanger body is reduced to have the upper ends of the jaws of the pinch grip to extend beyond the upper flange of the hanger body. This configuration reduces the weight of the hanger and saves the raw material used to mold the hanger. The hanger is environmentally friendly. The hanger further has an elevated portion formed below a lower neck region of the hanger where the hook of the hanger mounted to the hanger body. The hanger body further has a raised rib extending throughout the entire length of the hanger body. | 52,232 |
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to a method for making a pita chip or crisp and other such products in a continuous sheeting operation. Specifically, the process involves cutting a sheeted dough into longitudinal strips, cooking these longitudinal strips to form tubes, and pressing these tubes with a nub press prior to cutting and finish cooking.
2. Description of Related Art
Pita bread is a type of flatbread typically a round pocket bread, believed to have originated in the Middle East. The baking process typically involves forming, by rolling, a flat dough disk that is baked in a hot oven, usually in excess of 500° F., on a flat support surface. The “pocket” inside the finished loaf is created during cooking when the outside layers of the bread are seared, thus forming a cap that impedes the release of steam from the interior of the bread. This trapped steam puffs up the dough in the middle of the bread forming a pocket. As the bread cools and flattens, a pocket is left in the middle that can be later stuffed for making sandwiches and the like.
Pita “chips” or “crisps” (these two terms are used interchangeably herein) can be made by cutting or chopping pita bread loaves into chip sized pieces. Making individual round pita bread loaves and cutting each loaf into chip sized pieces can be time consuming and is not conducive to an efficient, continuous operation. One prior art approach to this issue involves pressing a dough ball between two hot plates to form the pita loaf and then cutting the loaf into smaller chip sizes. This approach is referred to as a dough ball press method followed by chopping of the bread loaves. The dough ball press method is not particularly efficient and has not demonstrated desirable throughput rates on continuous or semi-continuous product lines.
One attempt at developing a continuous process that makes pita chips or crisps more efficiently than the dough ball press method can be found in U.S. Pat. No. 6,291,002 entitled “Method for Preparing Elongated Pita Bread” issued on Sep. 18, 2001, to inventor George Goglanian (the “Goglanian Patent”). The Goglanian Patent describes a process whereby dough is sheeted and then cut longitudinally into continuous strips. These strips are run through an oven, thereby producing a tube-shaped bread product. A tube shape, however, is not conducive to making into a flat chip, because cutting the resultant tube would yield shorter tube segments as opposed to flat chips. Consequently, the Goglanian Patent teaches cutting this tube along its longitudinal edges into two sections, a top section and a bottom section. When these sections are cut into chip shapes, the sections fall away from each other, thus making chips of both the top and the bottom of the tube.
The process described in the Goglanian Patent produces a pita chip or crisp with only one side having the characteristic pita bread exterior texture. The other side of the chip comprises the interior of the cooked tube and, therefore, presents a different texture than the outside surface. Further the Goglanian Patent requires the cutting step that separates the top half of the tube from the bottom half of the tube. This step requires special cutting equipment and leads to product loss during the cutting itself. While the Goglanian Patent can produce a chip from flatbread, it does not produce the pita chip similar to one made by chopping or cutting a round pita bread loaf.
Consequently, a need exists for a continuous pita chip process, along with the accompanying equipment, that can efficiently produce a pita chip having the exterior pita texture on both sides of the chip such that it resembles a pita chip made by cutting a traditional pita bread loaf. Such process should be capable of throughput rates typical of sheeter lines and, preferably, use equipment which provides for a minimal plant footprint.
SUMMARY OF THE INVENTION
In a preferred embodiment the invention mixes raw ingredients to produce a sheetable dough. In one embodiment, the dough is then subjected to a low stress sheeting step followed by a proofing step. After the dough is proofed it is cut, for example into longitudinal strips, and then proceeds continuously to a pita oven for cooking. Shortly after exiting the oven the cooked dough, now in a tube shape, is run through a nub press, which in a preferred embodiment is a pin roller. After this pressing step, the product is allowed to cool, is cut into chip shaped pieces, and is further cooked and seasoned prior to packaging.
The invention provides for a continuous process that produces a pita chip or crisp that resembles a pita chip made by cutting a traditional pita bread loaf into chips. Yet, such process provides for substantially increased throughput and minimal plant footprint.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred embodiment, further objectives and advantages thereof, will be best understood by reference to the following detailed description of illustrative embodiments when read in conjunction with the accompanying drawings, wherein:
FIG. 1 is flowchart of Applicants' method for making pita chips;
FIG. 2 illustrates cooked dough tubes exiting a pita oven as a part of Applicants' method;
FIG. 3 is a perspective view of a portion of one of the dough tubes of FIG. 2 ;
FIG. 4 is a perspective view of a chip produced by Applicants' invention;
FIG. 5 is a schematic of one embodiment of Applicants' oven and press combination; and
FIGS. 6 a , 6 b , and 6 c illustrate a preferred embodiment nub press pin roller of Applicants' invention.
DETAILED DESCRIPTION
Referring to FIG. 1 , Applicants' process starts with sheeting of a dough during a sheeting step 102 . In a preferred embodiment, this sheeting step 102 is a low-stress sheeting operation, typically involving two or more sheeter roller pairs, such that the thickness of the sheet is gradually reduced, thereby limiting the work imparted to the dough by the sheeters. In one embodiment, the dough sheet is sheeted 102 to a final thickness of approximately 0.0625 ( 1/16) inches to 0.1875 ( 3/16) inches. This dough sheet then continues down a conveyor system through a proofing step 104 , typically involving a proofer box or proofer.
A proofer is a type of food processing equipment that allows the dough to rise in a relatively warm and humid environment for a period of time before further processing. Proofing relaxes the stress in the dough and lets the yeast work. A proofer box is a chamber that is humidity and temperature controlled, for example at around 90° F. and about 50% relative humidity. The proofing time using Applicants' invention varies between zero minutes to twenty minutes, depending upon the amount of flour in the dough, the amount of yeast in the dough, and the preferred texture of the end product. For example, a softer textured product requires a longer proofing time than a harder textured product.
After exiting the proofer at the proofing step 104 , the dough continues down a conveyor through a continuous cutter at a cutting step 106 . In a preferred embodiment, this cutter cuts the dough into continuous longitudinal flat strips. However, the cutter can also make shapes other than longitudinal flat strips, such as longitudinal hexagonal shapes and longitudinal round shapes. In an alternative embodiment, the cutting step 106 can occur prior to the proofing step 104 .
The continuous longitudinal strips formed by the cutting step 106 continue along a conveyor and are spread apart by a spreading conveyor in order to input small gaps between the strips prior to entering a continuous pita oven where it is cooked during a cooking step 108 . These small gaps assure that the strip doesn't join back together during cooking 108 . In a preferred embodiment, the pita oven is a two zone oven set at 850° F. and 575° F. for zones 1 and 2, respectively, for a dwell time, in a preferred embodiment, of between six and thirty seconds, depending on product thickness and heat intensity. During this cooking step 108 , the longitudinal strips puff up, thereby forming a cavity in the center of each strip, as can be seen in FIG. 3 , resulting in tube-like longitudinal strips (or hollow ropes) exiting the pita oven, as can be seen in FIG. 2 .
Returning to FIG. 1 , after the cooking step 108 , these longitudinal tubes can be subjected to an optional cooling step 110 varying from zero seconds to fifteen seconds depending on the line speed required to achieve the desired texture and shape of the end product. For example, eliminating the cooling step 110 results in a harder product than conducting a cooling step 110 of up to fifteen seconds.
After the cooling step 110 , the longitudinal tubes are subjected to a pressing step 112 . In a preferred embodiment, this involves a nub press or pin roller, as will be described in more detail in reference to FIGS. 6 a , 6 b , and 6 c . This pin roller presses the interior surfaces of the tube together. Because this pressing step 112 occurs very shortly after the cooking step 108 , the dough inside the longitudinal tube is still somewhat pliable and tacky. Consequently, the pressing step 112 generally flattens the tube such that the inner surfaces of the pocket adhere in places, thereby forming a relatively flat, double layered product resembling a standard pita flatbread in its cross-section, but without the completely open pocket.
After the pressing step 112 this now generally flattened longitudinal strip is subjected to a second cooling step 114 that varies in time from zero to thirty seconds, depending on the cooling conditions and desired end product, prior to cutting into snack size pieces.
If a single layered pita chip resembling that described in relation to the Goglanian Patent is desired, the flattened tube is next subjected to a splitting step 116 . This splitting step 116 separates the flattened tube into a top and bottom strip. This step 116 is listed as optional, as the preferred embodiment maintains the upper and lower portions in contact to thus later form a food piece having two layers.
The flattened longitudinal strip is next cut in a cutting step 118 by, for example, a cutting roller that forms individual chip-sized pieces, such as is illustrated in reference to FIG. 4 . Finally, and again in reference to FIG. 1 , these individual pieces are finish cooked and seasoned 120 prior to packaging.
Each of the individual steps described in general with reference to FIG. 1 will now be described in more specific detail in relation to a preferred embodiment of Applicants' invention.
Table 1 below shows the dough formula used to produce a pita chip in accordance with this preferred embodiment.
TABLE 1 Ingredient Weight Percentage Wheat Flour 30-62 Whole Wheat Flour 0-31 White Whole Wheat Flour 1-2 Sugar 1-2 Salt 0-2 Oat Fiber 0-1 Yeast 1 Actual water 32-34
The raw ingredients listed in Table 1 are first fixed mixed to hydration in order to form a pliable dough. This can be done, for example, by a triple roller horizontal bar mixer. A typical mix time is between two and six minutes to a dough temperature of about 82° F. to 90° F.
Once the dough is formed, it is fed into a sheeter. The preferred sheeter utilizes three sets of sheeting rollers in order to progressively sheet 102 to a thinner sheet thickness while imparting a minimum amount of work into the dough during the process. A final sheet thickness of between 1/16 inch and 3/16 inch is preferred given the ingredients for the dough listed in Table 1.
The proofing step 104 is a continuous step that mimics the static resting of the dough in an environment with a constant temperature and humidity. This is accomplished by the use of a proofer box such as a continuous proofer with humidity and temperature control, which is a cascading multi-tier proofer designed to process a continuous dough sheet. Preferably, the proofer box used with Applicants' invention is maintained at a temperature of between 75° F. and 95° F. and a humidity level of between 45% and 65%. More preferably, the temperature inside the proofer is about 85° F. and about 55% humidity. The dwell time during the proofing step 106 is adjusted depending on the composition of the dough admix and the preferred texture of the end product. In relation to the dough composition disclosed in FIG. 1 , the dwell time in the proofer preferably ranges between one minute and fifteen minutes. Applicants most preferred embodiment using the dough described in Table 1 involves a proofing step at 85° F. and 55% humidity for a period of about eight minutes.
After exiting the proofer, the dough is subjected to a cutting step 106 , preferably cut into longitudinal strips that are 1.25 inches wide. As noted previously, the cutting step 106 can optionally occur prior to the proofing step 104 . After the cutting 106 , the longitudinal strips are slightly separated by a spreading conveyor in order to maintain some distance between each longitudinal strip as they proceed through the next step, the cooking step 108 . A gap of 0.125 inches is accomplished by the spreading conveyor in a preferred embodiment, but other distances are acceptable as long as the strips are not touching each other at their lateral edges.
Referring again to the dough made by the ingredients listed in Table 1, Applicants' preferred embodiment involves a continuous infrared oven with radiant, connective and conductive heat from both the top and bottom sides of the product conveyor. It is preferred to subject the dough made by the ingredients of Table 1 to a temperature of greater than 500° F. for a dwell time during the cooking step 108 of less than one minute. Doing so sears the exterior of the longitudinal dough strips causing capping layers on the exterior of the strips and a continuous cavity to form inside the strips. This makes the dough strips into partially-cooked bread tubes or hollow ropes. This can best be understood with reference to FIGS. 2 and 3 . In a preferred embodiment a two zone oven is used with temperature settings of 850° F. and 575° F. in zones 1 and 2, respectively, for a dwell time of between ten and fifteen seconds or, more preferably, about 12.7 seconds.
It should be noted that the cooking step 108 is only a partial cooking of the dough. In a preferred embodiment, the dough enters the oven at 42% water by weight and exits the oven at 32% water by weight, thereby reducing the moisture level of the dough during the cooking step 108 by less than 11%. The strips as they exit the oven are still pliable and somewhat tacky on the inside.
Referring to FIG. 2 , several of these bread tubes 220 are shown exiting the oven 250 immediately after the cooking step by way of a conveyor 252 . A perspective view of a cross-sectional portion of one of these tubes 220 is shown in FIG. 3 as a tube piece 320 . By viewing the piece 320 in cross-section, it can be seen that a cavity has formed between the upper layer 322 and the lower layer 324 . Also shown is one of the lateral edges 326 .
Returning to FIG. 1 , Applicants' method can incorporate an optional cooling step 110 depending on the environmental temperature and line speed. If a tube 220 is pressed together while the product is too hot, the interior cavity can be joined back together, so to speak, making the finished product harder. The cooler the product before pressing, the less bonding spots and the softer the finished product.
It should be noted that the cooling step 110 is, in any event, relatively short such that the partially cooked bread tubes are not allowed to set up or harden in the shape illustrated by both FIGS. 2 and 3 . Instead, the tubes are either immediately or within a short period of time after the cooking step 108 , and certainly no more than 15 seconds thereafter, subjected to the pressing step 112 . It is preferred that the internal temperature of the dough tube at the time of the pressing step 112 should be at least 140° F. and preferably of between 140° F. and 210° F. The purpose of this pressing step 112 is to collapse the tube and reform these continuous ropes into flat longitudinal strips. This is accomplished, in a preferred embodiment, by a device referred to as a nub press or pin roller. A nub press is a flat plate having protrusions or nubs that is periodically pressed onto the passing partially cooked bread tubes. A more preferable embodiment uses a pin roller such as illustrated in FIG. 6 . A pin roller is a cylindrical roller with protruding pins. Ideally, and as it is illustrated in FIG. 5 , this pin roller 562 is located in close proximity to the exit of the pita oven 550 such that the bread ropes or tubes that exit the oven 550 on the conveyor belt 552 are shortly thereafter subjected to the previously described pressing step. This pressing step, in a preferred embodiment, occurs continuously with the tubes proceeding along the conveyor 522 to be pressed between the pin roller 562 and a support plate 564 . Thereafter, the flattened strips continue along the direction indicated on the conveyor 552 to the next processing step.
Referring now to FIGS. 6 a , 6 b , and 6 c , a pin roller 662 is illustrated. FIG. 6 a shows a perspective view in elevation of the pin roller 662 . The pin roller 662 is mounted on a shaft 670 . The pin roller 662 consists of a curved surface interspersed with raised pins 682 . The pin roller 662 illustrated has an overall tube length 672 of 20.0 inches or 508 mm. Referring to FIG. 6 b , which is a side view of the pin roller 662 mounted on the shaft 670 , the height or outside diameter 676 of the tube 662 (not taking into account the pins 682 ) is 5.229 inches or 133 mm. Taking into account the pins 682 , the over diameter 674 of the pin roller 662 is 5.729 inches or 146 mm. In the embodiment illustrated, the height of each individual pin 682 from the tube surface of the pin roller 662 is 0.250 inches or about 6 mm. Further, the roller is spaced from the conveyor surface such that the end of the pins 682 are 1/16 inch away from the conveyor surface at the closest point.
FIG. 6 c is a cut away section of the pin roller surface flattened in order to illustrate the relative distance between the pins 682 and the pattern used. It can be seen that the pins 682 are arranged in a triangular pattern resulting in a series of vertical and horizontal rows. FIG. 6 c is oriented such that the horizontal rows of pins 682 are parallel to the shaft 670 and the vertical row of pins 682 are perpendicular to the shaft 670 . The vertical distance 688 between pins 682 in vertical rows is 1.0 inches or 25 mm, while the vertical distance 680 as between pins 682 in adjacent vertical rows is 0.50 inches or 13 mm. The horizontal distance 684 between adjacent vertical rows is 0.866 inches or 22 mm, while the horizontal distance 686 between two vertical rows separated by a third vertical row is 1.7320 inches or 44 mm. The roller 662 depicted, therefore, is 23 pins wide and 18 pins around. Each pin 682 has a spherical radius of 0.188 inches.
The pins 682 illustrated in FIGS. 6 a , 6 b , and 6 c provide for points of increased pressure along the bread tube during the pressing step. For a dough thickness out of the sheeter of about 3/32 inch, a press gap of 1/16 inch is preferred in order to impart the desired structure for a pita chip end product. The pressing with a nub press or pin roller of such configuration is preferable because it allows for a continuous process, providing controlled contact or press points without completely flattening the strips, which in turn contributes to the textural characteristics of the end product. The triangular pattern center of 1 inch is optimized for the thickness of the product to manage the span between the attachment points to minimize breakage. This varies depending on product thickness and strength.
Returning again to FIG. 1 , after the pressing step 112 is accomplished, the now flattened and partially cooked strips continue along a conveyor and are allowed to cool, typically in ambient conditions, for between 12 minutes and 20 minutes. Referring again to the dough formulation listed in Table 1, is it preferable for the formation of a pita chip that the dough be allowed to cool at this cooling step 114 for approximately 15 minutes.
If it is desirable to produce a pita chip wherein one side of the chip is characteristic of the outside surface of a pita and the other side of the chip is characteristic of the inside surface of the pita pocket, Applicants' invention can optionally employ a splitting step 116 that involves splitting the piece along its lateral edges. This can be done, by example, with a modified band saw typically used for cutting bread. In a preferred embodiment, however, the flattened strips proceed to a cutting step 118 , typically involving a cutting roller, that can cut the strips into chip sized shapes, such as rectangular shapes or triangular shapes. A rectangular shaped chip is illustrated in FIG. 4 , which shows a pita chip 420 with an upper surface 422 , a lower surface 424 , and two lateral edges 426 , 428 . It can be seen that this end product 420 exhibits an undulating exterior surface. The interior surface also maintains variations in the distance between the two distinct layers of the chip 120 produced by the process, such that in places the layers are physically connected and in other are separated slightly by small pockets of between 0.5 mm and 2.0 mm in height, for example.
After cutting the strips to form the chips 420 shown in FIG. 4 , the chips 420 are finished cooked and seasoned. This finish cooking can involve convection baking, hot air drying, microwave cooking, frying, or other finish cook methods known in the art in order to lower the end product moisture level to a desired end point. In a preferred embodiment, the moisture level is lowered to between 3% and 1% by weight. Thereafter, the finished product is packaged by methods known in the art.
Table 2 below shows the composition of a finished product in accordance with one embodiment of Applicants' invention. The ingredients are listed by weight percentage of the finished crisp.
TABLE 2
Finished Product Composition
Percentage
Wheat Flour
73.3
Salt
2.4
Sugar
1.8
Yeast
2.8
Oat Fiber
0.9
Vegetable Oil
17.4
Water
1.4
It should be noted that the entire process described as Applicants' preferred embodiment involves the continuous movement of the dough or product starting from the sheeting step through the finish cooking and seasoning step. The process is intended to take place using conveyors along with equipment that accommodates the continuous operation of each of the steps described. This allows for the continuous production of a flat bread type product without the need for the use of the dough ball and hot press equipment used in prior art. Equipment used in this continuous process is said to be ‘in communication,” because dough and/or product moves continuously from one piece of equipment (such as sheeter, proofer, oven, press, etc.) to the next piece of equipment.
Further, while Applicants' invention has been described with reference to a pita chip embodiment, the processing steps and equipment used with Applicants' invention and described herein are equally adaptable for producing any number of types of flat bread products on a continuous processing line, including crackers. Adjustments can be made to the initial dough composition and various processing parameters, including cooling times, oven temperatures, dwell times at various stages, and temperature and humidity during the proofing stage, to produce flat bread products of varying types and consistencies. For example, a differential speed in conveyors of 2:1 can be used between the proofing step and oven to create a cracker like texture in the final product by stretching the dough before cooking. It should be understood that Applicants' invention can substitute for the prior art dough ball and hot press method and equipment in order to produce any type of flat bread, such as the East Indian Naan bread, previously made by prior art methods but with the efficiencies and throughput of a continuous process.
While the invention has been particularly shown and described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention. | A continuous process for making a pita chip or other similar products using a continuous pressing step that occurs shortly after a continuous oven initial cooking step. Applicants' invention produces a final product with characteristics of a traditionally cooked pita chip using equipment that provides for significant increases in manufacturing throughput. The use of a continuous oven with the relatively concurrent pressing step allows for the production of a flat chip piece on a continuous product line. | 26,879 |
BACKGROUND OF THE INVENTION
Repair clamps for repairing leaks in pipes are well-known and widely used. Generally these clamps have a gasket overlain with a metal band encircling the pipe. These bands may be in the form of two half-circles, or a single full circle having a pair of flanges at the longitudinal joint. Bolt and nut assemblies usually connect these flanges and are tightened to draw the band (and the gasket) about the pipe over the leak. In the case of lines which are usually below ground, after excavating for a working area around the leak, the leaking fluid tends to collect in the area, making working conditions hazardous as well as unpleasant. As stated above, the present method of installing the repair clamp includes tightening the nuts on the bolts with a socket wrench or the like. This is relatively time-consuming.
SUMMARY OF THE INVENTION
It is accordingly a primary object of this invention to provide a tool for drawing together the flanges of a repair clamp in a rapid manner, and providing a tight shut-off while the clamp bolt-and-nut assemblies are being drawn up.
It is another important object of this invention to provide two lever systems in a tool, one for rapid closure while the resistance is relatively low, and a second for exerting considerably greater closing force.
It is another object of this invention to provide a method of rapidly and positively shutting off a leak from a fluid-filled pipe using a repair clamp assembly and the tool of the instant invention.
The instant invention is a compound tool designed for particular use with repair clamps useful in sealing leaks in fluid pipe lines, but also finding utility in other areas where spaced flanges are to be brought closer together. One prior art patent, U.S. Pat. No. 3,108,783, solves a portion of this problem in a very limited fashion, but does not envision anything like the solution presented herein.
The novel features which are considered as characteristic of the invention are set forth in particular in the appended claims. Also, a method of applying a repair clamp to a pipe is claimed. However, for a full understanding of the tool, attention is directed to the following embodiment, shown in the drawings and described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the tool of the instant invention;
FIG. 2 is an end view of the tool of FIG. 1; and,
FIG. 3 is a section along the line III--III of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The tool 10, as seen in FIG. 1, resembles in general outline a miniature of the clam-shell buckets used on heavy construction cranes. The pairs of jaws 12 and 12a and 14 and 14a move similarly to those aforementioned buckets. However, a handle assembly 16 is fixed to jaws 12 and 12a, and a screw-lever assembly 18 is connected between jaws 14 and 14a and ratchets 20 and 20a for a greater mechanical force application between the jaws 12 and 14.
By inspection of FIG. 2, it can be seen that the jaws 12 and 12a and 14 and 14a are each paired, as is ratchet plate 20 and 20a. Each pair operates as a unit, having cross-braces between them and a common axle 22 about which all of them rotate. For this reason, when the expression "jaw or "ratchet" is used in the singular, the plural is usually intended. The same is also true of the two-bar linkages 24 and 24a and 26 and 26a which connect jaws 14 to ratchet plates 20.
Referring now to the Figures, front jaws 12 and 12a are mounted to pivot about axle 22, and are joined adjacent the gripping surfaces 28 by a stiffener-cross member 30. These gripping surfaces 28 are adapted to engage one flange of a repair clamp, with the two front jaws 12 and 12a spaced to straddle one bolt seat. At the top of the jaws 12 and 12a as seen in the Figures, another stiffener-cross member 32, which also acts as a retainer for a spring 34 and has a protruding portion 36, projecting outwardly for a purpose to be discussed later, connects the two front jaws 12 and 12a and reinforces them with upstanding flange portions 38 and 38a fixed to jaws 12 and 12a, respectively.
Projecting rearwardly from front jaws 12 and 12a is the handle assembly 16. This assembly has a grip portion 40 at the extreme rear of the tool 10, which divides into a bifurcated member, each leg 42 and 42a being fixed to the outside of a front jaw, 12 and 12a respectively. The legs are fixed to their respective jaws by welding or other suitable means, and is located surrounding axle 22, with the legs having a suitable bore for receiving axle 22.
Pivotally mounted atop the front jaws is a pawl 44, which is biased into engagement with the teeth 46 and 46a of ratchets 20 and 20a, respectively, by pawl spring 34. Pawl 44 has fixed on either side, stub shafts 45 and 45a which are received in bores through flanges 38 and 38a, respectively, and front jaws 12 and 12a, respectively. The shafts 45 and 45a are axially retained in these bores by suitable means, such as washers 47 and retaining rings 47a. As is usual with a ratchet-pawl combination, front jaws 12 and 12a can move clockwise about axle 22 as seen in FIG. 1, with pawl 44 riding over the teeth 46 and 46a, but in order to move the front jaws counter-clockwise with respect to the ratchets, pawl 44 must be lifted out of engagement. A handle portion 48 projects forwardly generally parallel to and spaced apart from, the protruding portion 36 of the upper cross member 32. By grasping handle 48 and protruding portion 36, pawl 44 may be lifted clear of teeth 46 and 46 a, and this is free to move either way about axle 22. Stop members are provided to limit the relative movement of jaws 12 and 12a with respect to ratchets 20 and 20a. On the outside of ratchet 20, between ratchet 20 and jaw 12, an L-shaped stop member 50 is fixed to ratchet 20, with the horizontal leg 52 projecting toward jaw 12. This stop is positioned to contact cross member 30 in the position shown in the Figures, to limit the travel of jaws 12 and 12a in the counter-clockwise direction as seen in FIG. 1. Additionally, another L-shaped stop member 54 is fixed on the outside of jaw 12, with leg 56 turned inwardly towards ratchet 20. When jaws 12 and 12a are rotated clockwise as seen in FIG. 1, leg 56 contacts leg 52 on stop member 50, preventing pawl 44 from running off ratchet teeth 46.
The above-described front jaw-ratchet interaction, where the front jaws 12 and 12a are moved by handle 16 relative to ratchets 20 and 20a, is one lever assembly for fast closing action against relatively minor resistance. There is a second lever assembly for applying greater force, which will now be described. It was mentioned above that the ratchets 20 and 20a are connected to act as a unit. They have cross members similar to the lower cross member 30 of the front jaws 12 and 12a. One such cross member 58 is seen in FIG. 2, while the other cross member 60 is positioned on the axis of the connection journals of links 24 and 24a. These cross members 58 and 60 may be of any configuration that provides proper spacing of the ratchets 20 and 20a, and stiffens them so that they act together. It was found convenient to make cross member 58 of solid construction, while cross member 60 was made of hollow tubing (not shown), then a rod member 62 inserted through the tubing and projecting from the outer side of each of ratchets 20 and 20a, respectively, to provide a bearing for links 24 and 24a. This rod member 62 projects beyond the links on either side, and is fastened in place in any suitable manner. Peening the end of the rod is satisfactory, or retaining rings (not shown) received in suitable grooves in rod 62. The other end of link 24 (and of 24a) is journaled on a block 64 having its ends 65 and 65a shaped to receive the links 24 and 26 on one side, and 24a and 26a on the other. These link ends are fastened on the block using washer 66 and retaining ring 68 on each side.
Rear jaws 14 and 14a are similarly constructed to the front jaws and the ratchets to act as a unit. A cross member 70 is fixed between the jaws near the gripping surfaces 72 (which are similar to gripping surfaces 28 on the front jaws). Another cross member 74 is positioned at the axis of the journal of the connection with links 26 and 26a. Cross member 74 is constructed similar to cross member 60, with hollow tubing providing rigidity and spacing to the jaws 14 and 14a, and a rod 76 is inserted through the tubing and projecting from the jaws 14 and 14a to provide a bearing for links 26 and 26a, respectively. The links are connected to the rear jaws in the same fashion as the front links are fastened to the ratchet plates as described above.
Referring now to FIGS. 2 and 3, it will be seen that axle 22 is mounted in a longitudinal bore 78 in a block 80. A transverse bore 82 receives a threaded rod 84, which is fixed in place by a pin 86. A stop member 88 is fixed atop block 80 for a reason to be explained later.
Axle 22 has block 80 centered on its longitudinal axis and ratchets 20 and 20a fit against the ends of block 80. Abutting ratchets 20 and 20a on axle 22 are rear jaws 14 and 14a, respectively. Abutting rear jaws 14 and 14a are spacer washers 90 and 90a, respectively. Bearing against the outer surfaces of spacers 90 and 90a are front jaws 12 and 12a and attached handle legs 42 and 42a, respectively. Retaining the whole assembly on axle 22 are washers 92 and 92a retaining rings 94 and 94a, respectively.
Returning our attention to block 64 which has the links 24, and 26 and 24a and 26a mounted as pairs on respective ends, it can be seen by observing FIG. 3 that there is a transverse bore 96 through it aligned with bore 82 in block 80. Journaled in bore 96 is crank assembly 98. Crank assembly 98 has a stem 100 journaled in bore 96. Stem 100 has an enlarged portion 102 above block 64, which seats on a thrust bearing 104. Below block 64, another thrust washer, or bearing, 106 is retained in place by retaining ring 108 seated in a groove 110 in stem 100. A crank arm 112 and hand grip 114 provide the leverage to turn crank assembly 98. Stem 100 has a through bore 116, threaded on the bottom portion with threads 118 to match rod 84. The upper end of bore 116 is enlarged for provision of a stop member 120 fixed atop rod 84 by a capscrew 122.
It will thus be seen that the second lever system comprises a two-bar linkage with provision for changing the angle between the links, thus moving the rear jaws 14 and 14a with respect to ratchets 20 and 20a by means of a screw jack type of leverage. The stop 120 limits the upward movement of crank assembly 98, while stop member 88, fixed to block 80, limits the downward movement of the crank.
The foregoing describes a tool particularly useful in rapidly tightening leak repair clamps around a leak in a fluid pipe line. Referring to FIG. 1, in which the clamp is shown wrapped about the pipe at the point of leakage, the tool can be grasped by the hand grip 114 of the screw-lever assembly with one hand, and the grip portion 36 of the stiffner 32 with the other hand. The gripping surfaces 72 of rear jaws 14 and 14a are placed on one flange of the repair clamp, straddling a bolt with jaws 14 and 14a. The front jaws 12 and 12a are then lowered to contact the other flange of the repair clamp. Holding the screw lever assembly 18 in position with the hand holding grip 114, the other hand moves to grip 40 and is lifted (or brought toward the first hand). This moves front jaws 12 and 12a along with pawl 44, down over ratchet plates 20 and 20a and pawl 44 rides down teeth 46 and 46a of the ratchets. Upon encountering more resistance than the operator can overcome with this lever system, pawl 44 is allowed to seat itself in the nearest teeth of the ratchets, and the crank 98 is then turned to actuate the screw-lever assembly 18. By cranking crank assembly 98 downwardly on rod 84, the included angle between links 26, 26a and 24, 24a becomes greater, pushing ratchets 20 and 20a clockwise about axle 22 with respect to rear jaws 14 and 14a. Through engagement of teeth 46, 46a with pawl 44, front jaws 12, 12a are also rotated the same way, providing a much greater closing force between jaw surfaces 28 and 72 than was possible with the first lever system.
Upon attaining shut-off of the leaking fluid, the bolts of the repair clamp can be tightened, and the tool of the subject invention removed. To remove the tool after the clamp bolts have been tightened, one merely releases the pressure by reversing the rotation of crank 98 for a portion of a revolution, then the pawl 44 may be disengaged from the ratchet teeth 46, 46a, and the front jaws 12, 12a moved to their fully retracted position with respect to ratchets 20, 20a (that shown in FIG. 1). After removing the tool from the clamp, it is a good idea to fully retract the crank assembly 98--that position shown in FIGS. 1 and 3--to be ready for the next use.
It will be seen from the above description and the drawings that a novel tool and method of using it have been invented. | A tool for rapidly clamping a repair clamp tightly around a pipe. The tool has a two-stage operation, the first for rapidly taking up any slack, and the second for applying the necessary clamping force for tightening the clamp on the pipe. | 13,249 |
BACKGROUND OF THE INVENTION
1. Technical Field of the Invention
The present invention relates in general to thin film devices and more specifically to a method, apparatus and computer program product for identifying electrostatic discharge (ESD) damage to a thin film device.
2. Description of the Related Art
Magnetic head disk drive systems are widely employed in the computer industry as a cost effective form of data storage. In a magnetic disk drive system, a magnetic recording medium, in the form of a disk, rotates at a high speed while a magnetic read/write transducer, generally referred to as a magnetic head, elevates slightly above the surface of the rotating disk. The magnetic head is attached to or formed integrally with a “slider” that is suspended over the disk on a spring-loaded support arm known as an actuator arm. As the magnetic disk is rotated at its operating speed, moving air generated by the rotating disk in conjunction with the physical design of the slider operate to lift the magnetic head allowing it to glide or elevate slightly above and over the disk surface on a cushion of air, generally referred to as an air bearing. The height at which the magnetic head elevates over the disk surface is typically only a few microinches or less and is primarily a function of the disk's rotation, the aerodynamic properties of the slider assembly and the force exerted by the spring-loaded arm.
The magnetic head typically includes a magnetoresistive (MR) transducer or sensor element electrically connected to detection circuitry. MR sensors are well known in the art and are particularly useful as read elements in magnetic transducers, especially at high data recording densities. The MR sensor generally has a resistance that modulates in response to changing magnetic fields corresponding to magnetically encoded information. The detection circuitry detects the resulting changes in resistance by passing a sense current through the MR sensor and measuring the voltage drop across the MR sensor. The detected voltage signal is then used to recover information from the magnetic disk. The MR read sensor provides a higher output signal than an inductive read head. This higher output signal results in a higher signal to noise ratio for the recording channel and consequently permits higher area density of recorded data on a magnetic disk surface.
A major problem encountered during the manufacturing and assembly of magnetic heads is the buildup of electrostatic charges on the various elements of a magnetic head or other objects that come into contact with the magnetic head and the accompanying spurious discharges of static energy generated. For example, static charges may be generated by the presence of certain materials, such as plastics, during the manufacture and subsequent handling of the magnetic heads. These charges can induce or result in electrostatic discharge. The net effect of such a discharge often damages or degrades the MR sensor in reading data correctly.
Currently, the ESD screening regimes employed in the manufacture of MR sensors are typically of two general types. One approach is to employ a sampling method wherein a number of randomly chosen MR sensors are selected and undergo a detail inspection. This approach, however, may not catch all the sensors that may have suffered ESD damage. Another method is to take a first measurement of the resistance of every sensor prior to final fabrication and a second subsequent resistance measurement of all the sensors after final fabrication. The two resistance measurements are then compared with each other to identify potential ESD damage. This method, however, requires two measurements that increase the time required to fabricate a sensor.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a method, apparatus and computer program product for identifying electrostatic discharge (ESD) damage to a thin film device.
To achieve the foregoing object, and in accordance with the invention as embodied and broadly described herein, a method, apparatus and computer program product for identifying electrostatic damage to a thin film device is disclosed. The method includes (1) determining a cold resistance of the thin film device, (2) determining a hot resistance of the thin film device, (3) calculating a heating delta resistance (HDR) from the hot and cold resistances and (4) comparing the HDR to a threshold value to ascertain if the thin film device has suffered ESD damage. The HDR of the thin film device is characterized by the following relationship:
HDR=(hot resistance-cold resistance)/(cold resistance).
The present invention recognizes that there is a noticeable difference between the resulting heating delta resistance (HDR) value of a thin film device, such as MR sensor, that has suffered ESD damage from the HDR value of an undamaged device. The present invention utilizes this identified difference between the HDR values of a damaged and unaffected device to provide a more efficient and time effective screening mechanism that may be advantageously employed in, but not limited to, the manufacturing and fabrication processes of thin film devices.
In one embodiment of the present invention, the thin film device is a magnetoresistive (MR) sensor. In a related embodiment, the MR sensor is a ansitropic magnetoresistive (AMR) sensor. Alternatively, the MR sensor may be a giant magnetoresistive (GMR) sensor.
In yet another embodiment of the present invention, determining the hot resistance value of the MR sensor includes applying an operational current of the MR sensor. In an embodiment to be described in greater detail herein, the operational current ranges from about 4 milliamps to about 10 milliamps. In another related embodiment, on the other hand, determining the cold resistance of the MR sensor includes applying a current of less than 1 milliamp.
The foregoing description has outlined, rather broadly, preferred and alternative features of the present invention so that those skilled in the art may better understand the detailed description of the invention that follows. Additional features of the invention will be described hereinafter that form the subject matter of the claims of the invention. Those skilled in the art should appreciate that they can readily use the disclosed conception and specific embodiment as a basis for designing or modifying other structures for carrying out the same purposes of the present invention. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the invention in its broadest form.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
FIG. 1 illustrates a block diagram of an embodiment of a testing environment constructed according to the principles disclosed by the present invention;
FIG. 2A illustrates an exemplary graph of calculated HDR measurements for a plurality of AMR sensors that have been subjected to a simulated ESD versus ESD ΔR;
FIG. 2B illustrates an exemplary graph of calculated HDR measurements for a plurality of GMR sensors that have been subjected to a simulated ESD versus ESD ΔR; and
FIG. 3 illustrates a high-level process flow of an embodiment of an ESD screening process employing the principles disclosed by the present invention.
DETAILED DESCRIPTION
With reference now to the figures, and in particular, with reference to FIG. 1, there is depicted a block diagram 100 of an embodiment of a testing environment constructed according to the principles disclosed by the present invention. In the illustrated embodiment, a magnetoresistive (MR) sensor 110 , e.g., a thin film device, is shown coupled to a conventional current generator 130 and a data acquisition device 140 via first and second electrical conductors 120 , 125 , respectively. First and second electrical conductors are typically part of MR sensor 110 . Data acquisition device 140 is also shown coupled to current generator 130 and a controller 150 . In an advantageous embodiment, data acquisition device 140 is an analog to digital (A/D) circuit card that is resident in controller 150 . Data acquisition device 140 is used to control the current output of current generator 130 and to measure the voltage Vout across first and second electrical conductors 120 , 125 . It should be readily apparent to those skilled in the art that current generator 130 , data acquisition device 140 and controller 150 may also be embodied in an automatic testing equipment (ATE) such as a Hewlett-Packard HP4145B Semiconductor Parameter Analyzer.
Controller 150 , in an advantageous embodiment, is an IBM™ PC computer manufactured by IBM Corporation of Armonk, N.Y. It should also be readily apparent to those skilled in the art, however, that alternative computer system architectures may be employed. Generally, controller 150 , embodied in a PC computer, comprises a bus for communicating information, a processor coupled to the bus for processing information, a random access memory coupled to the bus for storing information and instructions for the processor, a read-only memory coupled to the bus for storing static information and instructions for the processor, a display device coupled to the bus for displaying information for a computer user, an input device coupled to the bus for communicating information and command selections to the processor and a data storage device, such as a magnetic disk and associated disk drive, coupled to the bus for storing information and instructions.
The processor may be any of a wide variety of general purpose processors or microprocessors, such as the i486™ or Pentium™ brand microprocessor manufactured by Intel Corporation of Santa Clara, Calif. However, it should be apparent to those skilled in the art that other varieties of processors may be utilized in a computer system. The display device may be a liquid crystal device, cathode ray tube (CRT), or other suitable display device. The data storage device may be a conventional hard disk drive, floppy disk drive, or other magnetic or optical data storage device for reading and writing information stored on a hard disk drive, floppy disk drive, or other magnetic or optical data storage medium.
In general, the processor retrieves processing instructions and data from a data storage medium using the data storage device and downloads this information into random access memory for execution. Thereafter, the processor then executes an instruction stream from random access memory or read only memory. Command selections and information input at the input device are used to direct the flow of instructions executed by the processor. The results of this processing execution are then displayed on the display device.
MR sensor 110 generally comprises a sensing element (not shown) composed of a ferromagnetic material that is enclosed by a shield made of a highly permeable magnetic material such as Permalloy or Sendust. The shield minimizes the magnetic interferences from affecting the sensing element and thereby producing extraneous electrical pulses. Conductive leads, i.e., first and second electrical conductors 120 , 125 , attach electrically at the end portions of the sensing element to provide a means for measuring the resistance of the sensing element.
As discussed previously, static electrical charges build up on the various components of the sensor assembly or on any object, equipment or person that may come into contact with the sensor. These charges are generated during the fabrication process and poses serious potential damage to the sensor. The electrical charges migrate from the areas at which they are generated to build up along conductive paths. The buildup of static charges subsequently discharge from one conductive element across a dielectric, which experiences “breakdown,” to another conductive element, in the manner of a capacitive discharge. The discharge typically causes damage by burnout or the like at the areas of the conductive material that function as terminals for the discharge of the stored static electrical energy.
The present invention recognizes that there is a noticeable difference between the resulting heating delta resistance (HDR) value of a thin film device, such as MR sensor 110 , that has suffered ESD damage from the HDR value of an undamaged device. The present invention utilizes this identified disparity between the HDR values of a damaged and unaffected device to provide a more efficient and time effective screening mechanism that may be advantageously employed in, but not limited to, the manufacturing and fabrication processes of thin film devices. The HDR is defined by the following relationship:
HDR=(hot resistance-cold resistance)/(cold resistance), where the hot resistance is the resistance of the MR sensor 110 when an operational current is applied to it. The cold resistance is the resistance of MR sensor 110 when a minimum current (typically 1 mA or less) is applied, i.e., no or nearly no Joule heating is generated during the measurement process.
The values of the operational and minimum currents are dependent on the type of MR sensor and materials used to construct the sensor. In the illustrated embodiment, MR sensor 110 is a ansitropic magnetoresistive (AMR) sensor. Alternatively, in another embodiment, MR sensor 110 is a giant magnetoresistive (GMR) sensor. With both AMR and GMR type sensors, the operational current is typically four to ten milliamps. Similarly, with both AMR and GMR sensors, the minimum current utilized for the cold resistance measurement is generally less than one milliamp.
The differences in the resistance values of the hot and cold resistances is a result of Joule heating within the sensor which is dependent on the heat capacitance of the sensor and the heat conductance of the materials surrounding the sensor; the HDR is a characteristic property of the sensor. The relationship between the HDR of a sensor and ESD damage incurred by the sensor is described hereinafter in greater detail with reference to FIGS. 2A and 2B.
Referring now to FIGS. 2A and 2B, there are illustrated exemplary graphs illustrating the HDRs of AMR and GMR sensors following the application of simulated ESD transients across the sensors. In particular, FIG. 2A depicts an exemplary graph 200 of calculated HDR measurements for a plurality of AMR sensors that have been subjected to a simulated ESD versus change in resistance ESD ΔR (where ESD ΔR is defined as R post ESD initiation—R pre ESD initiation). FIG. 2B depicts an exemplary graph 210 of calculated HDR measurements for a plurality of GMR sensors that have been subjected to a simulated ESD versus ESD ΔR. An ESD event is initiated by applying a 150 nanosecond exponential decay current pulse, i.e., Human Body Model (HBM) transient, across the MR sensor to simulate an ESD transient.
As illustrated in FIG. 2A, for the AMR sensors that have been damaged by the HBM transient, their calculated HDR values have decreased along with experiencing an increase in their overall resistance value. An AMR sensor that has encountered ESD damage typically suffers an increase in its resistance. For severely damaged AMR sensors, their HDR value is reduced to zero.
For the GMR sensors that have suffered damage due to ESD, as depicted in FIG. 2B, HDR decreases for those sensors that have a resistance increase of less than forty ohms. The HDR of a ESD damaged GMR sensor could be significantly higher than its initial HDR value or have a negative value if its resistance increase as a result of ESD damage is greater than forty ohms.
Referring now to FIG. 3, with continuing reference to FIG. 1, there is depicted a high-level process flow 300 of an embodiment of an ESD screening process employing the principles disclosed by the present invention. Process 300 is initiated, as depicted in step 310 , when the screening process is queued for execution. Next, as illustrated in step 320 , the cold resistance of MR sensor 110 is determined. This is accomplished by generating a reference current Iref, using current generator 130 , to simulate a minimum current of MR sensor 110 . In the illustrated embodiment of FIG. 1, controller 150 is executing an application program that instructs current generator 130 , through data acquisition device 140 , to initiate a current flow at a predetermined level and for a predetermined time. The minimum current is typically less than one milliamp. The value of the minimum current applied and the application period is dependent on the type of MR sensor under test and materials used to fabricate the MR sensor. Concurrent with the application of the minimum current, the voltage Vout across first and second electrical conductors 120 , 125 is measured by data acquisition device 140 that, in turn, provides voltage Vout to controller 150 . Controller 150 calculates the cold resistance of MR sensor 110 , as is well known in the art, by dividing voltage Vout by reference current Iref.
Following the determination of the cold resistance of MR sensor 110 , the hot resistance of the MR sensor 110 is determined as depicted in step 330 . The determination of the hot resistance value is analogous to the manner in which the cold resistance was determined. In the case of the hot resistance, current generator 130 supplies a reference current Iref at an operational level, generally four to ten milliamps for a period of less than one second. Again, controller 150 calculates the hot resistance value of MR sensor 110 by dividing the measured voltage Vout by reference current Iref. It should be noted that although obtaining the cold resistance value prior to obtaining the hot resistance value is the preferred sequence, as shown in the illustrated embodiment, the alternative sequence of first determining the hot resistance value prior to determining the cold resistance value may also be advantageously employed.
After obtaining both the hot and cold resistance values of MR sensor 110 , as illustrated in step 340 , the heating delta resistance (HDR) of MR sensor 110 is calculated. Using the previously determined hot and cold resistances, controller 150 calculates the HDR using the following relationship:
HDR=(hot resistance-cold resistance)/(cold resistance).
With the calculated HDR, controller 150 next, as depicted in step 350 , compares a predetermined threshold value with the HDR of MR sensor 110 to ascertain if MR sensor 110 has suffered ESD damage. The predetermined threshold value is calculated using the same process described above using a “good” or undamaged MR sensor to establish a baseline value. In other advantageous embodiments, the threshold value may be a constant value or, alternatively, a function of certain measured parameters of a batch of sensors, wafer or neighbouring heads on a wafer. The parameters, e.g., may be the stripe height, resistance or signal amplitude of the MR sensor. It should also be noted that the threshold value varies depending on the type of MR sensor under evaluation and type of materials employed to fabricate the MR sensor. Furthermore, the level of deviation of the HDR value of a MR sensor under test from the baseline HDR value used to screen a “failed” MR sensor is also dependent on the level of screening desired. For example, a more rigorous quality control standard may be implemented wherein MR sensors with HDR deviations larger than 2% are rejected. Typically, a baseline between 5 to 15% is employed. It should be noted that the baseline values utilized is very much design dependent.
It should noted that although the present invention has been described in the context of a computer system, those skilled in the art will readily appreciate that the present invention is also capable of being distributed as a computer program product in a variety of forms; the present invention does not contemplate limiting its practice to any particular type of signal-bearing media, i.e., computer readable medium, utilized to actually carry out the distribution. Examples of signal-bearing media includes recordable type media, such as floppy disks and hard disk drives, and transmission type media such as digital and analog communication links.
In a preferred embodiment, the present invention is implemented in a computer system programmed to execute the method described herein. Accordingly, in an advantageous embodiment, sets of instructions for executing the method disclosed herein are resident in RAM of one or more of computer systems configured generally as described hereinabove. Until required by the computer system, the set of instructions may be stored as computer program product in another computer memory, e.g., a disk drive. In another advantageous embodiment, the computer program product may also be stored at another computer and transmitted to a user's computer system by an internal or external communication network, e.g., LAN or WAN, respectively.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. | A method, apparatus and computer program product for identifying electrostatic discharge (ESD) damage to a thin film device. The method includes (1) determining a cold resistance of the thin film device, (2) determining a hot resistance of the thin film device, (3) calculating a heating delta resistance (HDR) from the hot and cold resistances and (4) comparing the HDR to a threshold value to ascertain if the thin film device has suffered ESD damage. The HDR of the thin film device is characterized by the following relationship: HDR=(hot resistance-cold resistance)/(cold resistance). | 22,038 |
This patent application claims priority to, and is a continuation of, U.S. patent application Ser. No. 13/888,281, filed on May 6, 2013, which claims priority to, and is a continuation of, U.S. Pat. No. 8,434,188 from U.S. patent application Ser. No. 12/212,809, filed on Sep. 18, 2008, which claims benefit of U.S. Provisional Patent Application No. 60/973,737, filed Sep. 19, 2007. These prior patent applications are hereby incorporated herein by reference for all purposes.
BACKGROUND
Field of the Invention
The present invention pertains to various building tools and methods related thereto. For example, the invention involves various methods and apparatuses for comfortably gripped and efficiently controlled building tools. Further, the invention involves various methods and apparatuses for high quality, durable and/or lightweight building tools.
Description of Related Art
Various tools have been known in the past for working with cements, concretes, mastics and/or muds to, for example, prepare, apply and/or finish a desired shape or smooth surface for various building surfaces. For example, some tools used for applying material to or preparing the surface of, for example, concrete, include trowels. These types of tools are typically hand tools that are used to apply materials for making and/or smoothing various building surfaces such as floors and walls and may be used to apply various materials to building surfaces. These tools may be used by skilled craftsman working on a number of surfaces for long periods of time during the work day. As such, a comfortable grip(s) may be particularly important in developing a most desirable building tool(s).
Referring to FIGS. 1A-1D , one typical prior art trowel including a trowel tang and blade is shown. A handle 110 for gripping is provided. The handle has a generally oval or round shape. In particular, referring to FIG. 1A , the trowel 100 includes a tang 150 that connects the trowel handle 110 to the trowel blade 105 . The tang 150 includes a handle connecting member 151 , a blade attachment member 152 , and a handle support member 153 (see FIG. 1D ) that all cooperate as a tang 150 in connecting the trowel handle 110 to the trowel blade 105 . In the view of FIG. 1A , the connecting member 151 has a slight curve to its upper half so as to reflect its shape on either side to somewhat follow the round sides of the handle 110 , but as shown below connecting member 151 has a side view that is substantially straight and vertical relative to the plane (horizontal when the trowel bottom surface of the blade is set on a horizontal surface) of the handle 110 and trowel blade 105 . In other words, when looking at the trowel handle from the top as shown in FIG. 1C , the front or forward surface of the connecting member 151 of the tang has some curve to the left and the right of the center line, but when looking at the side view shown in FIGS. 1B and 1D , that from top to bottom the connecting member 151 is substantially straight and vertical having only a very slight slant relative to perfect perpendicular. Further, the back surface of the connecting member 151 is substantially flat and also approximately perpendicular to blade 105 and main axis of the handle 110 . The very top, and a substantial portion of, the connecting member 151 , is also as wide as the handle 110 , so as to cover a forward face of the handle 110 , resulting in a very abrupt drop and bulky front end surface to the tang 150 .
Referring now to FIG. 1B , a side view of a prior art trowel and trowel tang is shown. As more clearly shown in FIG. 1B , the handle connecting member 151 is a substantially solid and straight member having a front surface 151 A and a back surface 151 B each with an approximately linear top-to-bottom and side-to-side slope. Further, the handle connecting member 151 has a narrow width measured from the front surface 151 A to the back surface 151 B. A typical trowel, for example, may have a handle connecting member 151 with a front-to-back width of approximately 1 cm (0.4 inches). The handle connecting member 151 is coupled at one end to the blade attachment member 152 at a connection point 154 slightly offset in a forward direction from the center of the blade attachment member 152 . This typical trowel has a connection point 154 so that the front surface 151 A meets the blade attachment member 152 at a point 154 A having a distance of approximately 9.5 cm (3.75 inches) from a front end 152 A of the blade attachment member 152 and the back surface 151 B meets the blade attachment member 152 at a point 154 B having a distance of approximately 11 cm (4.375 inches) from the front end 152 A of the blade attachment member 152 . Note that the front point 154 A has an abrupt angle that is approximately 90 degrees, and the back point 154 B has a slightly rounded connection point but is still approximately a 90 degree angle, with the vertical axis of the connecting member 151 being approximately perpendicular to the horizontal axis of the blade attachment member. As can be clearly seen from this side view in FIG. 2B , the handle connecting member 151 is also connected approximately perpendicular to the blade attachment member 152 . The typical trowel may have a handle connecting member 151 with an angle (denoted 165 ) relative to the blade attachment member 152 of approximately 85 to 95 degrees. The blade attachment member 152 is elongated laterally across the trowel blade 105 and has a short height and narrow width that is used for coupling the blade attachment member 152 to the trowel blade 105 . The typical trowel may have a blade attachment member 152 with a height and width both of approximately ⅔ to 1⅓ cm (0.25 to 0.5 inches). Substantially the entire top surface of the blade attachment member 152 is approximately parallel to the trowel blade 105 having no slope so as to be approximately the same height across its entire length, from its very forward most point at the end of section 152 A, adjacent the connection point 154 of the connecting member 151 and blade attachment member 152 of the tang 150 , and through the very rearward most end of section 152 B.
Referring to FIG. 1C , a top view of a typical trowel is shown. From this view it can be seen that the handle member 110 with front portion 150 is approximately ⅓ the width of blade 105 and oriented to the center of the blade width. The constant width of the blade attachment member 152 is also illustrated as width 1 F and 1 G at ends 152 A and 152 B of the blade attachment member 152 , respectively, and is the same in size. The blade attachment member 152 is mounted to the blade 105 at approximately the center of the blade width and extends across most of the blade 105 length. The handle 110 is held to the tang via a cap 115 and a nut or bolt 120 . Most notably in FIG. 1C , the handle connecting member 151 is very narrow along the length of the blade 105 . The top most portion 151 C of the handle connecting member 151 is also very narrow and abuts the handle front portion 150 , but is slightly narrow than the handle 110 and handle front portion 150 . In any case, there is little lateral top surface of the handle connecting member 151 available onto which a user may place their hand, palm or finger on comfortably.
As more clearly shown in FIG. 1D , showing the handle 110 and cap 115 in cross sectional taken along line 1 D and 1 E of the FIG. 1C top view, the handle connecting member 151 is connected at its other end to the handle support member 153 so as to be approximately perpendicular to the handle connecting member 151 and approximately parallel to the blade attachment member 152 and trowel blade 105 . As shown, the typical trowel may have the entire length of the handle support member 153 with an angle (annotated as 170 ) relative to the handle connecting member 151 angle of approximately 85 to 95 degrees, both relative to the plane of the blade attachment member 152 . As previously indicated, the typical trowel also has a handle connecting member 151 with an angle (annotated as 165 ) relative to the blade attachment member 152 of approximately 85 to 95 degrees. The handle support member 153 includes a forward portion 153 A and a rearward portion 153 B, both approximately parallel to each other and approximately perpendicular to the handle connecting member 151 . The rearward portion 153 B is substantially round in shape and thinner than the forward portion 153 A. The forward portion 153 A of the handle support member 153 is substantially square in shape and thicker than the rearward portion 153 B. The major lateral axis through hole of the handle 110 is substantially straight so that the substantially straight handle support member 153 may be assembled easily into the lateral through hole (from end to end of the handle 110 ) in the handle 110 . An inside forward portion of the trowel handle 110 is through hole is hollowed with a similar square shape of the handle support member forward portion 153 A such that the thickness and square shape of the forward portion 153 A of the handle support member 153 allows the trowel handle 110 to snugly fit onto the handle support member 153 and prevents side-to-side rotation about a center axis of the trowel handle 110 during use. An end cap 115 and end nut 120 , hollowed with a similar round shape, are attached to the end of the trowel handle 110 and handle support member 153 , respectively, so as to prevent front-to-back sliding of the trowel handle 110 during use.
The trowel handle 110 has a top surface 110 A and a bottom surface 110 B and side surfaces (not labeled), which together provide a user with a gripping area and have only slight curvature due to a gradually increasing width in the trowel handle 110 . The trowel handle 110 meets the handle connecting member 151 at a handle interface 145 (see FIG. 1A ) in such a way that both the top surface 110 A and the bottom surface 110 B of the trowel handle 110 are adjacent to a portion of the handle connecting member 151 and are approximately perpendicular therewith.
These types of tools, for example trowels, are typically designed to be held by the hand of a user in a single manner and orientation. For example, with the typical prior art trowel shown in FIGS. 1A-1D , the user would most comfortably grip the handle coming from a the direction of the back end of the trowel (end with the end cap 115 ) with their fingers, palm and thumb of one hand surrounding the central portion of trowel handle 110 . However, many users may find it more advantageous to shift, modify, and/or change the orientation of their method of holding the trowel or tool(s). Therefore, it is advantageous to build such trowel(s) or tool(s) to be comfortably gripped and efficiently controlled by the hand of a user in various manners and orientations so as to increase the comfort and control of such tools for various surfaces or for use during long periods of time.
In addition to being used on various surfaces and for long periods of time, these types of tools are exposed to various bumps, jolts and mechanical stresses, as well as corrosive substances in their use. Therefore, it is advantageous to build such tools to be cost effective, light in weight and durable against extensive use and stress as well as the corrosion from corrosive materials they are designed to work on (e.g., concrete, mastic, mud, etc.).
SUMMARY
The present invention is directed generally to building tools that have improved comfort in gripping and/or efficient control that may be easily used in various manners and orientations. Further, the present invention is directed generally to building tools that are high quality, durable, and lightweight so as to help reduce user fatigue that occurs from extended tool use. For example, various tools may connect a handle in approximately parallel orientation with and to a work object (e.g., tool blade) to be moved by means of the handle and manual hand motion. The handle and work object may be connected together by a connecting member (or connecting means) that is a sloped, angled, and/or substantially curved member, so that a user has increased hand orientation options and/or increased and improved control over the tool while gripping the handle and/or connecting member in various manners and orientations, now enabled, during use. In various embodiment(s), the connecting member (e.g., a tang for a trowel) may include at least one portion that is relatively gradually and/or notably sloped, angled, and/or curved structure that may reasonably provide a comfortable extension of the handle and not just connect the handle to the work object, but augment the gripping and control of the tool. Further, various tools may include a handle that is shaped to smoothly continue the slope, angle, and/or curvature of such handle connecting member so that a user may shift, modify, and/or change the orientation of his or her grip onto and/or along the handle connecting member so as to be closer to the work object to be moved, for increased control by comfortably overlapping his or her hand onto at least a portion of the handle connecting member. This may result in a handle connecting member that is an alternative and/or extension of the gripping locations that are available with the handle alone.
Still further, various tools may include a handle connecting member having construction whereby a portion of the sides of the handle connecting member are removed so as to reduce the weight of the tool and may be designed in such a way as to increasing the structural integrity of the handle connecting member. For example, the handle connecting member may be formed, at least in part, with an I-beam or ribbed structure or cross-section.
Yet further, various tool(s) may include a connecting member or means formed to connect the handle to the object to be moved (e.g., a blade) having additional means of an attachment member (e.g., blade attachment member) that is elongated laterally across the object to be moved, and may be at least partially gradually sloped downwardly (or built up or taller in various locations). For example, the attachment member may be at least partially gradually sloped downwardly from the point(s) where connected to the handle connecting member, so as to increase the strength of the connecting means and/or the connection point(s). Further, the at least partially gradually sloped downwardly attachment member may add little weight and maintaining most of the distance between the handle and itself and the object to be moved to ensure sufficiently large distance for comfortable gripping without obstructing a user's fingers or hand. Still further, the connecting member may have a narrower width closer to a connecting point to an attachment member (e.g., blade attachment member) than at a location that interfaces or abuts a handle portion. And still further, the connecting member may have, for example, a ¼ circle radius on both an upper surface and a lower surface such that the two surface (and the entire outer surfaces of the handle and connecting member) approximately follow one another in a relatively smooth circular radius or curvature that narrows the width of the connecting member from a location against which the handle rests and the connection point to the blade attachment member (e.g., following a reducing circumference along the front length of the handle that is the general design shape of the handle). Yet even further, various tools may be made, at least in part, using a material including, for example, magnesium for the connecting member and/or the attachment member (e.g., trowel tang) to help reduce the weight of the tool.
In various embodiment(s), a trowel may include(s) a tang that may connect(s) the trowel handle to the trowel blade. The trowel may be, for example, a concrete trowel including a cross-ground trowel, a flat back end finishing trowel, a round/round finishing trowel, etc. A handle connecting member may be included with the tang and may assist the tang in coupling the trowel handle to the trowel blade. A handle support member may also be included with the tang and may be attached to the handle connecting member in such a way that at least a portion of the handle support member is approximately parallel with the trowel blade. A blade attachment member may further be included with the tang and may be attached to the handle connecting member and elongated laterally across the trowel blade. The handle connecting member may be a sloped, angled, and/or substantially curved member having a cross section that is thicker in one area than another. In various embodiments, the handle connecting member may be a larger circular shape where it interfaces to the handle and taper to a smaller round or oval shape in an area close to where it connects to the blade attachment member. In the case where the handle connection member is substantially curved, the handle connecting member may have a curved top/front surface and a curved bottom/back surface that approximately follows the curvature of the top/front surface. In one variation, the top/front surface may be substantially convex (as viewed from the top surface perspective) and the bottom/back surface may be substantially concave (as viewed from the bottom surface perspective) so as to approximately follow the curvature of the top/front surface and curve toward a major axis of the trowel handle. In another variation, the handle outer surface may be curved and may be shaped so to follow the curvature of the top/front surface and the bottom/back surface of the handle connecting member until the handle is approximately parallel to the trowel blade. In this case, the smooth transition between the handle and the handle connecting member permits a user to shift his or her normal forward grip in a lateral direction toward and/or over or around the handle connecting member for increased control of the trowel blade while maintaining a comfortable lower forward grip. In addition, the sloped design and/or smooth transition between the handle and the handle connecting member may also facilitate a user reversing the orientation of his or her lower forward grip by 180 degrees for dealing with various surfaces or action with the trowel while maintaining a comfortable reverse grip. In this case, the user's palm may rest comfortably even though it is primarily on the connecting member. In still another variation, the handle connecting member may have an I-beam construction whereby a portion of the sides of the handle connecting member are removed so as to reduce the weight of the trowel without reducing the structural integrity of the handle connecting member. In yet another variation, the blade attachment member may be gradually sloped from approximately the point where connected to the handle connecting member, so as to increase the strength of such connection point between the handle connecting member and the blade connecting member. In yet another variation, the trowel may be made, at least in part, of a magnesium material so as to create a more light weight trowel. For example, the trowel tang may be made of a magnesium alloy or metal including magnesium.
Still further aspects included for various embodiments will be apparent to one skilled in the art based on the study of the following disclosure and the accompanying drawings thereto.
BRIEF DESCRIPTION OF THE DRAWINGS
The utility, objects, features and advantages of the invention will be readily appreciated and understood from consideration of the following detailed description of the embodiments of this invention, when taken with the accompanying drawings, in which same numbered elements are identical and:
FIGS. 1A-1D depict a prospective view, side view, top view and partial cross-sectional side view, respectively, of a traditional trowel;
FIG. 2 is a perspective view of an exemplary trowel, according to at least one embodiment of the invention;
FIG. 3 is a side view of an exemplary trowel, according to one embodiment of the invention;
FIG. 4 illustrates a typical gripping on the handle area of an exemplary trowel, according to at least one embodiment of the invention;
FIGS. 5A-5B illustrates two of the possible forward gripping orientations of an exemplary trowel, according to at least one embodiment(s) of the invention;
FIGS. 6A-6B illustrate two of the possible reverse gripping orientations of an exemplary trowel and the inclusion of removing some material along a connecting member, according to at least one embodiment of the invention;
FIG. 7 is a top view of an exemplary trowel, according to at least one embodiment of the invention;
FIG. 8 is a cross-sectional view of an exemplary trowel of FIG. 7 taken across the line A, according to at least one embodiment of the invention;
FIG. 9 is a front view of an exemplary trowel, according to at least one embodiment of the invention; and
FIG. 10A-10C are cross-sectional views of an exemplary trowel of FIG. 9 taken across the lines 920 A- 920 B, 925 A- 925 B, and 930 A- 930 B, respectively, according to at least one embodiment of the invention.
DETAILED DESCRIPTION
The present invention is directed generally to building tools that are comfortable to grip and efficient to control in various manners and orientations. The present invention is also generally directed to building tools that are high quality, durable and in some cases lightweight. As such, the present invention includes various embodiments showing various apparatuses and methods for working with, for example, concrete, masonry, mastic, mud(s), finishing drywall, etc. Various embodiment(s) are directed to a trowel that may typically be used for applying and/or smoothing various building surfaces such as floors, walls, etc.
Various embodiments of the present invention are directed to a new geometry of the tang and handle of hand tools, for example trowels, floats, etc., that may be used for working with concrete, masonry, mastics, muds, adhesives, etc. in the building trades. Historically, these types of hand tools have had tang and handle configurations that were connected to one another and to a blade at approximately right angles (as show by the prior art trowel show in FIGS. 1A-1D described above), leaving the only comfortable grip area to be on the handle portion. The present inventions “Grip Right” or “EZ Grip” has been designed with ergonomics so as to provide a feel good grip(s) that has multiple comfortable gripping areas and orientations so that the tool may be gripped high or low along a handle and handle connection member area (e.g., a full tang—handle length) so that a worker's hand feels comfortable and remains feeling good even after many hours of working with the tool. The present invention handle and handle connecting member may also be designed so that the handle and handle connecting member may be gripped comfortably closer to the tools working member (e.g., trowel blade) to increase directional control of the tool for precision performance. For example, the handle and handle connecting member may have a smooth transition, the handle-to-tool connecting member and handle may have a curved radius shape to fit into the palm or support the fingers of a worker's hand, and/or the handle-to-tool connecting member may be at an angle or slope to the handle and/or the working portion of the tool. The invention may also include various other unique aspects, like the use of an I-beam type construction to increase the strength of the handle connecting member while maintaining a light weight structure. The invention may also include various aspects relating to the tang to blade connecting feature where the tang has a non uniform geometry where it has a taller cross sectional height where the blade is attached. This further increases the strength of the tool while keeping the weight as a minimum. In any case, the present invention marks a significant advancement in hand tool handle and connecting member design that increase the ease, comfort and versatility of working with the hand tool(s). This is particularly true for the embodiments of trowels and/or floats described below, but as one skilled in the art would understand, the generalities of the present invention may be applied to various other handle and handle connection applications and be equally useful.
Referring now to FIG. 2 , an exemplary trowel 200 according to one embodiment of the invention will now be described. A trowel 200 includes a tang 250 that connects the trowel handle 210 to the trowel blade 205 . The tang 250 includes a handle connecting member 251 and a blade attachment member 252 that assist the tang 250 in coupling the trowel handle 210 to the trowel blade 205 . The blade attachment member 252 is elongated laterally across the trowel blade 205 and is coupled at one side to the trowel blade 205 . The handle connecting member 251 is coupled at one end to the blade attachment member 252 at a connection point 254 and at another end to the handle 210 . In this case, the handle connecting member 251 may be a substantially curved member having a curved top/front surface 251 A and/or a curved bottom/back surface 251 B, each with an approximately non-linear top-to-bottom slope. In one variation, the top/front surface 251 A may be substantially convex (as viewed from the top and front sides) and/or the bottom/back surface 251 B may be substantially concave (as viewed from the bottom and back sides) so as to curve toward a major axis of the trowel handle 210 . The bottom/back surface 251 B may approximately follow the curvature of the top/front surface 251 A so as to be approximately parallel thereto. In one variation, the handle connecting member 251 narrows from top-to-bottom when looking at it from the side and from the front. The substantially curved top/front surface 251 A may have a convex curvature from approximately the location where it meets the trowel handle 210 at the handle interface 245 , to the location where it meets the blade attachment member 252 at a point 254 A. In order to provide a smooth connection between the top/front surface 251 A and the blade attachment member 252 , the substantially convex curvature of the top/front surface 251 A may transition to being concave (as viewed from the top and front sides) at an inflection point 254 A shortly before reaching the blade attachment member 252 . This permits the top/front surface 251 A of the handle connecting member 251 to gradually become parallel with a top surface of the blade attachment member 252 , rather than having an abrupt angle formed at point 254 A. This curved transition may help to strengthen the connection point 254 A and provide a comfortable surface for resting a portion of a user's hand. The substantially curved bottom/back surface 251 B may have a concave curvature (as viewed from the bottom and back sides) from approximately the location where it meets the trowel handle 210 , at the handle interface 245 , to the location where it meets the blade attachment member 252 at a point 254 B. In order to provide a smooth connection between the bottom/back surface 251 B and the blade attachment member 252 , the substantially concave curvature of the bottom/back surface 251 B may remain concave past a point 254 B where the bottom/back surface is perpendicular to a top surface of the blade attachment member 252 . This permits the bottom/back surface 251 B of the handle connecting member 251 to gradually become parallel with a top surface of the blade attachment member 252 . These substantially curved surfaces ( 251 A and 251 B) of the handle connecting member 251 also provide a location sufficiently parallel to the trowel blade 205 so that a user may comfortably rest or surround his or her hand in order to apply a force in a direction perpendicular and/or parallel to the trowel blade 205 . This area of the connecting member 251 is thus designed to not only support the handle 210 , but also so that it may be used itself as a hand support and/or grip area (by itself or in conjunction with the handle 210 ) and may provide increased control over the trowel blade 205 during use because a user's hand may reside closer to the connection point 254 and trowel blade 205 . It is also noteworthy that the interface location 245 between the handle connecting member 251 and the handle 210 may be in a forward direction and angled toward the front of the trowel 200 at an angle that is not substantially perpendicular to the lateral axis of the handle 210 .
In another variation, the handle connecting member 251 may be a substantially rounded member having a rounded top/front surface 251 A and/or a rounded bottom/back surface 251 B, each with an approximately non-linear side-to-side slope. Of course, the top/front surface 251 A and the bottom/back surface 251 B may meet at a location on the side of the handle connecting member 251 so that the handle connecting member 251 has an approximately circular or oval shape. These substantially rounded surfaces ( 251 A and 251 B) of the handle connecting member 251 provide a smooth, comfortable, and ergonomic location that a user may rest or surround his or her hand during use. In various embodiments, the handle connecting member 251 and at least a portion of the handle 210 may share a radial centerline axis 260 that is a smooth arc from connection point 254 into approximately one fourth of the handle 210 that is closest to the handle connecting member/handle interface 245 . In one variation, the handle connecting member 251 may be both a substantially curved member from top-to-bottom and a substantially rounded member from side-to-side. In this case, the substantial curvature of the handle connecting member 251 permits a user's hand to rest on or surround the handle connecting member 251 in order to apply a force in a direction perpendicular and/or parallel to the trowel blade 205 , while the substantial roundness of the handle connecting member 251 increases the comfort of such action. Of course, in at least one variation, rather than being curved, the connecting member front/top surface and/or back/bottom surface, may be substantially straight and at an angle relative to the plane of the blade 205 and lengthwise axis of the handle 210 .
In still another variation, the handle connecting member 251 may have a widened width measured from the front surface 251 A to the back surface 251 B. For example, the handle connecting member 251 may have a front-to-back width of approximately 1.5 to 2.5 cm (0.6 to 1.0 inches) that may vary along the radial curved center axis of the handle connecting member 251 . At the lower location near the connection location 254 , the thicker width may provide an increase in the strength of the handle connecting member 251 with the blade attachment member 252 so that significant forces being applied by a user to the handle and/or handle connecting member 251 by a user during use of the trowel 200 does not break the tang. The thicker width may also provide a user with a more substantial support or grip structure so that a user may more comfortably and ergonomically rest or grasp the handle connecting member 251 .
In yet another variation, the trowel handle 210 may also be a somewhat curved member having a curved top/front surface 210 A and/or a curved bottom/back surface 210 B, each with an approximately non-linear or curved top-to-bottom slope. The top/front surface 210 A may be somewhat convex and/or the bottom/back surface 210 B may be somewhat concave so as to curve from the outer surfaces of the handle connecting member 251 toward a major axis of the trowel handle 210 . The curvature of the top/front surface 210 A and/or the bottom/back surface 210 B of the trowel handle 210 may continue or follow the curvature of the top/front surface 251 A and/or the bottom/back surface 251 B of the handle connecting member 251 . In one exemplary embodiment shown in FIG. 2 , the curvature of the trowel handle 210 , however, continues only until a major axis of the trowel handle 210 is approximately parallel with the blade attachment member 252 and trowel blade 205 . Further, a shallow circular or oval indentation where a user's thumb or index finger might be placed on the top/front surface 210 A of the handle 210 while gripping in a normal forward manner may provide a comfortable and ergonomic grip (see, for example, the top view in FIG. 7 , item 765 ). This shallow indentation may only be a slight aberration in the curvature of the top/front surface 210 A so that the top/front surface 210 A may still be said to continue the curvature of the top/front surface 251 A of the handle connecting member 251 . In order to provide a smooth transition between the handle connecting member 251 and the trowel handle 210 , the front-to-back width of the trowel handle 210 near the handle interface 245 also follows the front-to-back width of the handle connecting member 251 (and visa versa). In this case, the smooth transition between the trowel handle 210 and the handle connecting member 251 effectively adds length to the available hand support or grip area because a user's hand may comfortably, easily, and ergonomically overlap the handle interface 245 onto the top/front surface 251 A and bottom/back surface 251 B of the handle connecting member 251 . Although not shown clearly in FIG. 2 , the sides of the trowel handle 210 and the handle connecting member 251 may also be coincident, at least at the handle interface 245 . The hand support or grip area, therefore, may be enlarged to consist not only of the top/front surface 210 A, at least portions of the side surfaces, and the bottom/back surface 210 B of the trowel handle 210 but also the top/front surface 251 A, at least portions of the side surfaces, and the bottom/back surface 251 B of the handle connecting member 251 . As the tang 250 including the handle connecting member 251 may be made, at least in part, of metal, the enlarged hand support or grip area may include metal.
In still another variation, the tang 250 may be made completely, or at least in part, of a material including magnesium, aluminum, long fiber carbon or glass filled materials, etc., so as to create a more light weight trowel. The material including magnesium may be magnesium alloy. For example, a magnesium alloy such as AZ31C containing approximately the following approximate percentages of materials: Magnesium: Al: 2.5-3.5%; Cu: 0.05% max; Fe 0.005% max; Mn 0.20% min; Ni 0.005% max; Si 0.30% max; Zn 0.60-1.40%; Ca 0.30% max; OT 0.30% max; Mg the remainder %. This composition or alloy of Magnesium may be particularly useful for forming parts by extrusion. Further, the formulation may have variations from those above, for example, the composition of magnesium may vary within the above by +/−5% for Al and Mg, and +5% on Mn. Another useful magnesium compound or alloy, may include the following substances in the following amounts: Aluminum (Al) at 8.5% to 9.5%; Copper (Cu) at 0.25% maximum; Manganese (Mn) at 0.15% minimum; Nickel (Ni) at 0.01% maximum; Silicon (Si) at 0.20% maximum; Zinc (Zn) at 0.45% to 0.9%; other materials (OT) at 0.30% maximum; and Magnesium (Mg) is the % remainder. This composition of Magnesium may be particular good for forming parts by casting. Further, other formulations are possible, such as the formulation of the magnesium alloy may vary within the above by +/−5% for Al and Mg, and +5% on Mn. The trowel blade 205 may be made of high carbon steel covered with a clear coat or from Stainless Steel.
The blade attachment member 252 and handle connecting member 251 may be part of an integral tang 250 made of the same material or may be welded together and made of the same or different materials such as materials including, for example, aluminum and/or magnesium. Of course, one skilled in the art would appreciate that a connecting member or tang of lightweight magnesium alloy may be useful in coupling a blade and a handle for a variety of other hand tools or other applications not specifically described herein where desired ergonomics, weight, durability, gripping and strength may be similar to the trowel described herein as exemplary embodiments.
The present invention may be made using the following process. The trowel 200 may be assembled form various parts. The handle 210 may be typically molded from various types of plastic and may (but need not) have an over-molded soft surface such as a thermoplastic elastomer. The tang 250 described in detail above may be produced by a casting process which produces a nearly finished part directly out of the mold. Cleaning excess parting line material from the casting process and machining the tang attachment features may complete the process for these parts. The trowel blade 205 may be stamped from hard sheet metal. In this manner, the blade 205 blank may then have fastening studs, or posts welded in place along the center of the blade. These studs may match mating holes machined into the base of the tang. The posts and mating holes may be spaced approximately 1-2 inches apart. The tang 250 may then be pressed onto the posts permanently securing the tang to the blade. The handle 210 may then be assembled onto the tang 250 and secured with an end cap (similar to FIG. 1 ) or plug (not shown in FIG. 2, 315 in FIG. 3 ) and nut 220 or nut 220 alone.
Referring now to FIG. 3 , this embodiment shows a side view of a trowel 300 as viewed from the left side. Although not shown, the right side view may be a mirror image of the left side view. The trowel 300 of this embodiment is similar to the trowel in the embodiment shown in FIG. 2 , but includes an angled handle connecting member 351 that may be connected to the blade attachment member 352 at a forward position with increased strength due to an inclined upper surface of the blade attachment member 352 near the connection point 354 . In this case, the handle connecting member 351 may be connected to the blade attachment member 352 in such a way that a major axis of the handle connecting member 351 along the line from “ 3 A” to “ 3 B” has an angle or slope, C ( 360 ), relative to a major axis of the blade attachment member 352 along the line from “ 4 A” to “ 4 B” of approximately 30 to 60 degrees. In a preferred embodiment, the angle or slope, C ( 360 ), between the handle connecting member 351 and the blade attachment member 352 is, for example, approximately 45 degrees. The slope may vary between, for example, approximately 20 degrees and approximately 75 degrees. This angle or slope, C ( 360 ), of the handle connecting member 351 relative to the blade attachment member 352 may provide increased control over the trowel blade 305 while gripping the trowel handle 310 . As this angle or slope, C ( 360 ), may also contribute to determining the area or distance, D, in between the trowel handle 310 and the blade attachment member 352 , the angle or slope, C ( 360 ), may be sufficient to provide an area along the bottom/back surface 310 B of the handle 310 that may be gripped by a user's finger(s) or hand. For example, with the handle connecting member 351 at an angle of approximately 45 degrees relative to the blade attachment member 352 , the area between the bottom/back surface 310 B of the trowel handle 310 and the blade attachment member 352 may be approximately 2.5 to 3.5 cm (1 inch to 1.3 inches). Further, the angle or slope, C ( 360 ), may also be sufficient to provide an area along the bottom/back surface 351 B of the handle connecting member 351 that may be gripped by a user's finger(s) or hand. For example, with the handle connecting member 351 at an angle of approximately 45 degrees relative to the blade attachment member 352 , the area between the bottom/back surface 351 B of the handle connecting member 351 and the blade attachment member 352 may be approximately 1.5 to 2.5 cm (0.6 inches to 1 inch).
The handle connecting member 351 may also be connected laterally along the blade attachment member 352 at an approximately forward connection point 354 toward the front end of the blade attachment member 352 A. For example, the trowel 300 may have a connection point 354 so that the front surface 351 A meets the blade attachment member 352 at a point 354 A having a distance of, for example, approximately 6.5 to 7.5 cm (2.5 to 3.0 inches) from a front end 352 A of the blade attachment member 352 and the back surface 351 B meets the blade attachment member 352 at a point 354 B having a distance of, for example, approximately 10 to 11 cm (4 to 4.375 inches) from the front end 352 A of the blade attachment member 352 . This forward connection point 354 may provide increased control over the trowel blade 305 while gripping the trowel handle 310 , especially where the handle connecting member 351 is substantially curved and may thereby shift the position of the trowel handle 310 more towards the rear of the trowel 300 .
The connection point 354 between the handle connecting member 351 and the blade attachment member 352 may be strengthened by forming it to have included a gradually sloping top surface, for example, at least a portion of an upper surface of the blade attachment member 352 on either side, or both sides, of the connection point 354 . A forward sloping surface 352 C (shown as a dashed line) may gradually incline from the front end 352 A of the blade attachment member 352 to a point 354 A where the top/front surface 351 A of the handle connecting member 351 meets the blade attachment member 352 . Of course, the forward sloping surface 352 C may begin its gradual incline from any point along the entire length of the blade attachment member 352 between the front end 352 A and the point 354 A. Likewise, a rearward sloping surface 352 D (shown with dashed line) may gradually incline from any point along the rear of the blade attachment member 352 , for example, at a midpoint thereof or near end 352 B of the blade attachment member 352 , to a point 354 B where the bottom/back surface 351 B of the handle connecting member 351 meets the blade attachment member 352 . Of course, the rearward sloping surface 352 D (shown with dashed line) may also begin its gradual incline from any point along the entire length of the blade attachment member 352 between the rear end 352 B and the point 354 B. In one embodiment like shown in FIG. 2 , the rearward sloping surface 352 D may begin its gradual incline from approximately the center of the length of the blade attachment member 352 between the rear end 352 B and the point 354 B. These inclined surfaces ( 352 C and 352 D) may provide additional structural strength to the connection point 354 so that a user may apply additional force to the trowel handle 310 and handle connecting member 351 without fracturing or breaking the trowel tang at connection point 354 . This is particularly important when using lighter weight material(s), such as a magnesium alloy or compound as the tang material, that is less strong.
Referring now to FIGS. 4, 5A-5B, and 6A-6B , various embodiments of the present invention are shown that include exemplary manners and orientations in which a user may grip the exemplary trowel. FIG. 4 shows a side view of a trowel 400 having one exemplary unique tang design according to at least one embodiment of the present invention and illustrate it as being gripped in a fairly typical or normal forward manner. As shown, when gripping the trowel in a forward manner the user's hand 425 (in this example the user's left hand shown in dashed lines) is gripping the trowel handle 410 only with the fingers encircling the sides and lower handle area 410 B, while the palm of the user's hand and the thumb abut the upper handle surface 410 A. In this case, the hand gripping is achieved entirely on the handle 410 and does not touch, cover or encroach on the handle connecting member 451 . The user's arm in this grip is approximately parallel with the major lateral axis of the handle 410 and the major lateral axis of the blade attachment member 452 . This is a fairly typical user's grip as is used with typical trowel and trowel tang designs (e.g., FIGS. 1A-1D ). Further, with this particular tang design, having an approximately 45 degree slope of the handle connecting member 451 , and hand 425 with grip illustration shown in FIG. 4 , one can see that the distance D between the bottom surface 410 B and top of the blade attachment member 452 provides plenty of room for the user's fingers when gripping the handle 410 in the forward manner. In fact, the slope of the handle connecting member 451 may be change to approximately 30 degrees and still provide sufficient distance D, with or without the increased height 425 D of blade attachment member 452 .
Referring now to FIG. 5A , a side view of a trowel 500 is shown according to one embodiment of the present invention and includes further exemplary illustrations of how a user may grip the handle 510 and handle connection member 551 in a lower forward manner. In one exemplary manner, the hand 525 (shown in dashed lines) may be shifted forward and downward onto the tang ( 550 ) so as to cover a portion of the handle connecting member 551 and the handle 510 . As shown, in this gripping manner the index finger of the hand 525 may surround the back/underside surface 551 B and the thumb may abut a portion of the front/top surface 551 A of the handle connection member 551 . The thumb side of the palm of the hand 525 may cover the interface 545 between the handle 510 and the handle connection member 551 . In one variation, the thumb of the user's hand 525 may be advanced lower on the front/top surface 551 A of handle connection member 551 so as to the be adjacent to or abut the upper surface of the front portion 552 A (or surface 552 C) of the blade attachment member 552 . In any case, the index finger of hand 525 may comfortably rest against or abut the lower back concave area where the handle connection member 551 and the back part of blade attachment member 552 meet. Furthermore, if the tang includes strengthening slope 552 D on the back portion of blade attachment member 552 , the index finger may also abut or rest on this raised surface also, while the distance D is sufficient for the index finger to comfortably fit into this are of the tang. These forward gripping positions are facilitated by the angled and smooth transition handle connection member 551 and may provide more stable control of the trowel during various uses.
Referring now to FIG. 5B , a side view of a trowel 500 is shown according to one embodiment of the present invention and includes a grip similar to the grips shown in FIG. 5A in a lower forward manner. However these exemplary grips are modified so that the top/front surface 551 A of the handle connecting member 551 is used as primarily a hand grip support with much of the palm of the hand 526 resting on the handle connection member 551 . In these cases, the index finger of the hand extended so that the tip of the finger rests along the top/front surface 551 A of the handle connection member 551 . Alternatively, the index finger may be extended ( 526 A) so that the index finger tip rests on the front portion 552 A of the blade attachment member 552 while the rest of the index finger no longer rests on the top/front surface 551 A of the handle connection member 551 . In this case, the palm of the hand 526 (shown in dashed lines) may be shifted forward a bit so that most of the palm of the hand straddling interface 545 is forward of interface 545 . As such, the middle finger may then abut the curved surface in the rear of the connection area 554 between the handle connecting member 551 and the blade attachment member 552 . Once again, these forward gripping positions are facilitated by the angled and smooth transition handle connection member 551 and may provide more stable control of the trowel during various uses.
Referring now to FIG. 6A , a side view of a trowel 600 according to one embodiment of the present invention is shown that includes a cut out side area 651 C and another exemplary hand 625 (shown in dashed lines) grip orientation, a reverse grip. In this example, a lower reverse hand grip orientation is shown. In the lower reverse hand grip orientation, approximately one half of the palm of the hand 625 may rest comfortably on the forward/top surface 651 A of the handle connecting member 651 and may straddle interface 645 between handle connecting member 651 and the handle 610 with a large portion of the palm resting on the forward most portion 610 A of the handle 610 . The four fingers may surround the sides and the lower/back portion 651 B of the handle connecting member 651 and the sides and lower portion 610 B of the handle 610 , with the majority of the finger grip area being on the handle 610 . Although, the butt of the palm of the hand 625 rests squarely on the handle connecting member 651 and provides the primary force during working with the trowel 600 . Given the smooth radial curvature of the handle connecting member's 651 front/top surface 651 and bottom/back surface 651 B, a comfortable and controlled reverse hand grip is enabled and there are no abrupt angles or edges on the trowel tang that may cause discomfort or blisters from extended reverse hand grip use of the trowel. In this embodiment the pinky finger may fit comfortably in the rounded rear facing surface of the connection area of the handle connecting member 651 and the blade attachment member 652 at connection area 654 as a result of sufficient distance D. This embodiment also shows that the pinky finger may abut the bottom/back surface 651 B of the handle connecting member 651 and may abut the top of the blade attachment member 652 , particularly if a slope 652 D is provided.
Further, the exemplary trowel shown in FIG. 6A includes a cut-away, indent, or valley area 651 C in the side of the handle connecting member 651 . The opposite side of the handle connecting member 651 may be symmetrical to the side shown in FIG. 6A . This area may help to reduce the weight of the tang and trowel, with little or no loss of the strength of the handle connecting member 651 by forming an I-beam type cross section of the handle connecting member 651 . This variation will be described in more detail below with reference to FIGS. 8-10C .
Referring now to FIG. 6B , an exemplary side view of a trowel 600 according to one embodiment of the present invention is provided and includes a hand 626 (shown in dashed lines) exemplary gripping in a lower reverse manner, but the grip has been modified so as to rotate the grip, move it slightly further toward the back of the trowel and handle, and extend the index finger across the top surface 610 A of the handle 610 while moving the thumb (also shown in dashed lines) to the far side of the handle 610 . Although the hand 626 fingers and thumb orientation is moved further toward the back of the handle 610 , the primary pressure point of the hand 626 remains the palm area of the hand 626 and the butt of the palm of the hand 626 rests squarely on the handle connecting member 651 , particularly on the front/top surface 651 A of the handle connecting member 651 . Again, in this manner and orientation of gripping, the handle connecting member 651 may be the primarily hand support mechanism while the handle with the fingers and thumb orientation thereon may become a control arm for proper orientation and movement of the trowel 600 . Once again, in this embodiment the pinky finger may fit comfortably in the rounded rear facing surface of the connection area of the handle connecting member 651 and the blade attachment member 652 at connection area 654 . The pinky finger may also abut the bottom/back surface 651 B of the handle connecting member 651 and may abut the top of the blade attachment member 652 , particularly if a slope 652 D is provided.
Referring to FIG. 7 , a top view of an exemplary trowel 700 , according to at least one embodiment of the present invention is shown. In this embodiment a thumb indent 765 has been added to the handle 710 and the I-beam cut away 751 C has been indicated on the handle connection member 751 , but is not the primary embodiment shown. The top view illustrates the rectangular shape of the blade 705 having straight sides. One skilled in the art recognizes that the blade may be one of many other shapes or designs, for example rounded, notched, irregular, etc., depending on the intended use of the trowel 700 . The blade attachment member 752 of the tang is shown in this view as having ends 752 A and 752 B, and a width or thickness of 7 F which may be in the range of, for example, 0.8-1.2 cm (¼ to ½ inches). Although the width may be wider, this exemplary range has proven sufficient for the stresses that this trowel will typically experience, even when the tang is made of lighter and less strong materials such as a metal including magnesium. The handle connection member 751 may be tapered from a narrow width equal to the width of 7 F (e.g., 0.8-1.2 cm (¼ to ½ inches)) where it connects to the blade attachment member 752 up to a width of, for example, 2.5-3.5 cm (⅞ to 1⅜ inches) at the interface 745 of the handle connection member 751 and the handle 710 . In preferred embodiments the width of the handle 710 and the abutting portion of the handle connection member 751 are made to be the same size so that there is a smooth transition in dimension between the two members. The width of the handle 710 at its widest portion may be, for example, 3.5 to 4.5 cm (1⅜ to 1⅞ inches), but may be made to any width as long as it fits comfortably in a user's hand. The far end of the handle 710 may be rounded. As will be seen more clearly in FIGS. 9 and 10A-10C , the handle may also preferably have a rounded or oval cross-section so that a user's hand may fit comfortably around it. As noted above, the handle may include a thumb indent or detent 765 where a thumb may comfortably set when the handle 710 is gripped in a typical forward manner. Further, the handle 710 may be attached to the tang using a plug, spacer or washer 715 and a nut or bolt 720 . A cross-sectional line 6 D- 6 E is provided so that a cross-section of handle 710 may be provides and the handle support member may be clearly seen and explained relative to FIG. 8 below.
Referring now to FIG. 8 , a partial cross-sectional view (handle section 810 ) of an exemplary trowel of FIG. 7 taken across the line 7 F- 7 F in FIG. 7 is shown, according to at least one embodiment of the invention. In this Figure it is shown that the tang may also include a unique handle support member 853 . The handle support member may have three separate areas, handle orientation portion 853 A, handle attachment stud 853 B and handle rotation reduction mechanisms 835 C that operate to ensure proper handle 810 mounting, connection, and orientation. As can be seen, the handle support member 853 and the hollow center interior of the handle 810 have two different angles incorporated therein. Various angles 800 C, 800 G, and 800 E are shown for the various different slopes of the tang and handle support portions as illustrated with lines 800 A- 800 A, 800 B- 800 B, and 800 D- 800 D. These angles and slopes are different than traditional trowel tangs and handle support configurations, and enable manufacturability of the curved or angled hand grip to the tang and comfortable gripping of the tool. As such, the handle support member 853 and hallowed out center interior of handle 810 have at least one angle that is not parallel with the plane of the blade 805 or the blade connecting member 852 axis. In this embodiment, the main axis 800 A- 800 A of the handle orientation portion 835 A is at an angle 800 C, which may be, for example, approximately 10 to 20 degrees from the approximately horizontal axis 800 B- 800 B of the handle axis stud 853 B (which is approximately parallel with the lateral main axis 800 F 0 800 F of the blade attachment member 825 ). (Compare to FIG. 1D that shows a straight handle support member 153 .) As noted previously, angle G (formed by axis 800 D- 800 D and 800 F- 800 F) may be approximately 45 degrees and may be formed at a larger or smaller angle as desired. The rotation reduction mechanisms 853 C may be triangular shaped protrusions that are located approximately in the center of each side of a square shaped handle orientation portion 853 A. The square shape of the handle orientation portion 853 A may provide the primary proper orientation and rotation reduction for the handle 810 , and the rotation reduction mechanisms 853 C may provide secondary rotation reduction and may result in the hollow end (female) of the handle 810 appear in a pattern, for example an 8 pointed star shape, to match. Finally, the far hollow or hollowed out end of the handle 810 may be capped with a holed pug 815 through which a threaded end of the stud 853 B may slide through. A nut 820 may then be threaded onto the threaded end of the stud 853 B so that the plug and handle may be secured to the handle support member and pulled tight against the handle connecting member 851 at the interface 845 , so as to be securely attached to the tang.
Referring now to FIG. 9 , a front or forward perspective view of an exemplary trowel is shown, according to at least one embodiment of the invention. This view clearly shows the indented sides 951 C on the left and right sides forming an I-beam shape on the handle connecting member 951 . The handle 910 is shown to be at the top of the handle connecting member 951 . The blade 905 is coupled to the bottom of the blade attachment member 952 . The top of the blade attachment member 952 is attached to the bottom of the handle connecting member 951 . Further, the handle connection member 951 may have a thicker top portion G and thinner bottom portion F, so as to smoothly transition from the interface with the handle 910 and the width of the blade attachment member 952 to improve the comfort of gripping the handle 910 and handle connecting member 951 . Cross-section lines 920 A- 920 B, 925 A- 925 B, and 930 A 930 B, are provided to better indicate the removal of portions of the left and right side of the handle connecting member 951 , as will be shown in FIGS. 10A-10C .
Referring to FIG. 10A-10C , cross-sectional views of an exemplary trowel of FIG. 9 with exemplary portions of the handle connecting member 910 removed to reduce weight, as taken across the lines 920 A- 920 B, 925 A- 925 B, and 930 A- 930 B in FIG. 9 , respectively, are shown, according to at least one embodiment of the invention. These figures show the varying cross sections of the connecting member 951 . With respect to FIG. 10A , this is a cross-sectional view taken across line 930 A- 930 B as provided by this exemplary embodiment. In this case the cross-section is taken high on handle connecting member 951 close to the handle 910 interface in and area that does not have material removed and is solid 1010 . As shown, this area of the handle connecting member 951 is approximately an oval or egg shape 1005 . With respect to FIG. 10B , this is a cross-sectional view taken across line 925 A- 925 B as provided by this exemplary embodiment. In this case the cross-section is taken at approximately the middle section of the handle connecting member 951 and shows how material has been removed from the left side 1015 and right side 1020 of the handle connecting member 1051 . As shown, in this exemplary embodiment the removal of material on the left side 1015 and right side 1020 results in an approximately I-beam shaped cross-section. With respect to FIG. 10C , this is a cross-sectional view taken across line 920 A- 920 B as provided by this exemplary embodiment. In this case the cross-section is taken at the lower portion of the handle connecting member 951 and shows how material has been removed from the left side 1025 and right side 1030 of the handle connecting member 1051 . As shown, in this exemplary embodiment the removal of material on the left side 1015 and right side 1020 results in an approximately I-beam shaped cross-section, albeit somewhat large on one side. As shown, the I-beam construction may have one portion thicker than another, e.g., the back/rear area may be thicker than the front portion. Although the reduced weight and removal of material in this exemplary embodiment results in an approximately I-beam shape, one skilled in the art would appreciate that material may be removed in a number of different ways and resulting shapes, and still provide sufficient weight reduction and strength for the material used to construct the tang and/or handle connection member 951 .
Various processes may be used for forming the tang. One process includes injecting material into a mold having the desired geometry. If the material is metal such as Aluminum or magnesium a casting method may be used. If the material is a plastic, an injection molding process may be used. These processes may be used to create all or any part of the tang. In any case, once cast or injected, the mold may be opened and the part(s) may be removed. The part(s) may require minor finishing to complete, if there are some imperfections relative to the final desired shape(s). Another variation may be to insert mold a piece of stronger material imbedded inside a less strong lighter material.
Although a particular embodiment(s) of the present invention has been shown and described, it will be understood that it is not intended to limit the invention to the preferred embodiment(s) and it will be obvious to those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the present invention. Thus, the invention is intended to cover alternatives, modifications, and equivalents, which may be included within the spirit and scope of the invention as defined by the claims. Accordingly, the scope of the present invention should be determined not by the embodiments illustrated above, but by the claims appended hereto and their legal equivalents. | The present invention is directed generally to building tools with improved comfort in gripping and/or efficient control that may be used in various manners and orientations. A handle and work object (e.g., trowel blade) may be connected together by a connecting member (or connecting means) that may be a sloped, angled, and/or substantially curved member, so that a user has increased hand orientation options and/or control over the tool while gripping the handle and/or connecting member in various manners and orientations. In various embodiment(s), the connecting member (e.g., a tang for a trowel) may be a relatively gradually and/or notably sloped, angled, and/or curved structure that may reasonably provide a comfortable extension of the handle and augment the gripping of the tool. The various tools may include a handle connecting member having construction whereby a portion of the sides of the handle connecting member are removed. Magnesium may be used. | 63,966 |
STATEMENT OF GOVERNMENT INTEREST
The U.S. Government has a paid-up license on this invention and the right in limited circumstances to require the patent owner to license others on reasonable terms as provided for by the terms of contract No. NAS5-38014 awarded by the National Aeronautics and Space Administration.
FIELD OF THE INVENTION
This invention relates generally to superconducting quantum interference devices (SQUIDs), and more particularly to a highly symmetrical, ultralow-noise DC SQUID configuration.
CROSS-REFERENCE TO RELATED PATENTS
U.S. Pat. No. 5,053,834 to Simmonds is hereby incorporated by reference to the extent that the disclosures and teachings thereof are required for an understanding of or support for this invention.
BACKGROUND OF THE INVENTION
Superconducting quantum interference devices (SQUIDs) are the most sensitive magnetic flux detectors currently available. They have extensive versatility in being able to measure any physical quantity that can be converted to a magnetic flux, as for example a magnetic field, a magnetic field gradient, current, voltage, displacement and magnetic susceptibility. The applications for SQUIDs are quite extensive. The SQUID susceptometer has been widely used by scientists in laboratory applications for many years, but more recent advances in SQUID technology have greatly expanded its use beyond the laboratory. In the medical arena, SQUIDs are more commonly being used in magnetoencephalography and magnetocardiology, wherein SQUID magnetometers are used to measure the tiny magnetic signals generated in the brain and heart respectively. SQUIDs have also been used with superconducting magnets to create magneto-ferritometers for monitoring iron levels in the liver. In the commercial marketplace, the military has expended considerable development effort on a variety of SQUID applications. SQUIDs have also found many applications, in geophysics, from prospecting for oil and minerals to earthquake prediction through the use of active and passive SQUID systems. SQUID technology is also useful for non-destructive evaluation, including both the integrity evaluation of structures and the location of submerged or buried structures or members.
SQUIDs combine the physical phenomena of flux quantization and the Josephson effect. Flux quantization means that the flux (Φ) through a closed superconducting loop is quantized in units of the flux quantum (Φ o ≅h/2e≅2.07×10 -5 Wb)). The Josephson effect occurs at "boundaries" between superconducting regions of superconductor structures. Such boundaries may be achieved in a number of known ways. "Grain boundary" junctions occur at crystalline grain boundaries and are further discussed in Char et al., U.S. Pat. No. 5,157,466. Boundaries of the "tunneling type" occur where a very thin insulator is interposed between two superconductors. SNS junctions use a very thin normal conductor or weakly superconducting material as the boundary. Nanobridge junctions use a severely restricted area of superconductor to form a weak link, and are further discussed in Kapitulnik, U.S. Pat. No. 5,219,826.
In general, a SQUID comprises a superconducting loop that is broken in at least one place by a Josephson junction. There are two kinds of SQUIDs. The first, the rf SQUID, uses a single Josephson junction to interrupt the current flow around a superconducting loop, and is operated with a radiofrequency flux bias. The second, is the dc SQUID, which has two or more Josephson junctions interrupting a superconducting loop and is biased with a steady or "DC" current bias. Recently, thin film technology has been applied to SQUID construction, making the design of dc SQUIDs more commercially practical. Both the rf and dc SQUID concepts are readily understood by those skilled in the art, and will not be detailed herein. Those not as knowledgeable with SQUID technology and theory of operation are referred to "SQUIDs: Theory & Practice," John Clarke, New Superconductivity Electronics, Kluwer Academic Publishers, 1993, incorporated herein by reference.
In simple terms, a dc SQUID is a magnetic flux-to-voltage convertor, since it provides an output voltage across the Josephson junctions which varies as a function of the total magnetic flux applied to its superconducting loop. The output voltage is periodic in the applied flux, with a period of one flux quantum. By applying a dc bias current and dc flux to the SQUID, to set a quiescent voltage output level, magnetic fields producing a flux in the SQUID of much less than a single flux quantum (Φ o ) can be detected by measuring the deviation of the SQUID output voltage from the quiescent value. The dc SQUID is the most sensitive detector of magnetic flux available, and displays an enormous frequency response extending from dc to several GHz. The design of a SQUID determines the intrinsic performance of the device. It has been shown that the energy resolution of a low-inductance SQUID operating at 4.2K can approach the quantum limit. Besides the "rf" and "DC" SQUID distinctions, the physical nature and the resultant performance characteristics of a SQUID are related to the type of superconductor material(s) used in its fabrication. Historically, the early superconductors and resultant SQUIDs made therewith exclusively used "low-temperature" superconductor materials that display superconductivity near absolute zero. The use of low-temperature superconductor materials requires them to be placed in liquid helium at 4.2K (-269° C.). SQUIDs and magnetometers and other devices made therefrom are now commonly fabricated using single or multiple-layer thin film depositions and photolithographic and etching techniques well-known in the semiconductor industry. Low-temperature SQUID devices typically use Josephson junctions formed from stacked horizontal superconductor films such as niobium, which are aligned parallel to the substrate.
More recent discovery of higher temperature superconductive materials which display superconductive properties at temperatures over 77K, have increased the accessibility of SQUID technology. The higher temperature superconductors allow for operation in liquid nitrogen (at 77K), rather than in the much more expensive liquid helium. The higher temperature materials are generally referred to as high transition temperature "high-T c " superconductors or simply "HTS" materials. Ceramics are the most common HTS superconductor materials used in SQUID technology, with the most popular being YBa 2 Cu 3 O 7-x (most commonly called YBCO), which has a transition temperature of approximately 90K. HTS SQUID devices typically use a vertical Josephson junction technology, where the plane of the junction is perpendicular to the substrate, as for example junctions produced by grain-boundaries between two contiguous regions of a superconductor material having different grain or crystal orientations on either side of their juncture. While the present invention will be described with respect to its implementation in a low-temperature superconductor dc SQUID configuration, the principles of this invention apply equally well to SQUIDs employing HTS materials. In order to simplify explanation of the invention, the following discussions and descriptions will be made with reference only to low-temperature superconductors and dc SQUID configurations made therefrom. It will be understood, however, that the invention is not to be limited thereby.
To ensure low-noise operation, a "bare" dc SQUID typically is a low inductance device. A bare SQUID has a low effective flux capture area, resulting in a magnetic field resolution that is insufficient for many applications. Therefore, in practical SQUID magnetometer applications, the SQUID is often coupled to an input circuit generally having one or more pick-up loops or coils of superconductive material capable of capturing much more flux than the relatively small SQUID loop, therefore significantly increasing the magnetic field resolution of the device. Signals from the pick-up loop(s) can be either "directly" or "inductively" coupled to the SQUID loop. In low-temperature SQUID configurations excellent inductive coupling can be implemented by means of a multi-layer transformer configuration using thin film lithographic techniques. In such devices, the thin film superconductor SQUID inductance material is typically formed in the shape of a washer and is covered by an insulating layer on top of which is grown a thin film spiral superconductor coil with as many as several tens of turns, which acts as an input or transformer coil to inductively couple or transfer signals from the input coil to the underlying SQUID inductance loop. The input coil in turn is physically connected to an appropriate external magnetic flux pick-up loop.
The thin film "washer" design implementation achieves low inductance in the SQUID loop and tight coupling to multi-turn input coils by making the loop into a slotted groundplane. A second, thin film modulation coil is usually integrated on top of the SQUID washer as well, in order to couple a flux modulation signal to the SQUID. This is essential for operation of the device using conventional flux-locked loop readout electronics.
This approach has significantly advanced SQUID technology for numerous applications. However, unless the SQUID is heavily damped, the parasitic elements (i.e., capacitance and inductance) that are invariably introduced can lead to numerous resonances in the SQUID dynamics. These resonances manifest themselves as strong irregularities in the current-voltage (I-V) and in the voltage-flux (V-Φ) characteristics, leading to excess noise and making operation using conventional flux modulation techniques extremely difficult. Overdamping the SQUID may reduce the excess noise, but it also diminishes the amplitude of the SQUID output signal, placing more stringent demands on the readout electronics. To be useful for a wide variety of applications, a dc SQUID with transformer coupling of the input and modulation coils must meet several general requirements including: inductance matching of the input inductance to the load inductance, insensitivity to ambient fields, negligible coupling of the modulation signal to the input circuit, negligible coupling of the bias and modulation signals to the SQUID, and low-noise performance. To date, there have been few dc SQUID devices that adequately address all of these requirements.
Considerable effort has been devoted to the design of dc SQUIDs having low noise. Most approaches use a multi-layer design consisting of an input coil integrated on top of the SQUID inductance. In double washer designs wherein the washers are configured to form a gradiometer which rejects the effects of uniform fields, the bias current which must pass through the Josephson junctions may magnetically couple into the SQUID loop. This can result in an undesirable interaction that can introduce noise and drift into the SQUID sensor from the drive electronics. Further, introducing the bias current into the junctions in a non-symmetrical manner can also make the SQUID unduly sensitive to common mode noise which may be picked upon the bias leads that run from the electronics drive package at room temperature, down to the SQUID sensor in the cryogenic environment. Such common mode noise becomes an undesirable influence on the output signal.
In addressing these issues, U.S. Pat. No. 5,053,834 to Simmonds used a symmetrical dc SQUID system having two input coils and two modulation coils symmetrically arranged on a monolithic substrate such that the system nominally has no mutual inductance between groups of signal coils and modulation coils when the SQUID is biased for normal operation. The Simmonds SQUID response is gradiometric, and the Josephson junctions are in parallel with the input and modulation secondaries in order to keep the total SQUID inductance and flux noise low. The Simmonds configuration is designed to prevent bias current flowing into the junctions from coupling to the SQUID loop, to make the device more insensitive to fluctuations or noise in the bias current circuitry, and to prevent common mode noise on the bias leads, modulation coils or signal coils from coupling into the SQUID, but does not optimize device performance for applications which require detection of extremely weak currents. For such applications the equivalent rms current noise at the SQUID input is a much more relevant figure of merit than the rms flux noise, which is addressed by the Simmonds design. The present invention provides an improved dc SQUID design which incorporates the advantages provided by a symmetrical SQUID configuration while providing improved performance over prior art designs.
SUMMARY OF THE INVENTION
The present invention provides an improved multiple loop dc SQUID configuration with input and modulation circuitry configured for high symmetry and low-noise operation. The configuration is adaptable to simplified implementation using readily available standard thin film fabrication techniques, to provide a highly reliable device. In a preferred implementation of the invention, the SQUID inductance is defined by a plurality of washer-shaped, thin superconducting films symmetrically oriented on a substrate and connected in series to form a multiple-washer gradiometric structure. The series configuration offers significant rejection of uniform background magnetic fields without the risk of setting up possibly large circulating screening currents. Each washer has a hole at its center, with a slit running from the hole to the outer edge of the washer where the washers are joined. The slit in each washer is covered by a superconducting groundplane. Each washer, together with its hole and slit, forms a single turn secondary for an input or modulation coil. In a preferred configuration, there are four such washers connected in series in a symmetrical "cloverleaf" pattern; however, it will be understood that the invention is not limited to any particular number of washers, and that the preferred embodiment illustrated herein is for illustration purposes only. In the preferred structure, two oppositely situated washers are joined together at the center of the structure, and the other two oppositely situated washers are connected together through two Josephson junctions located one per washer, at diagonally opposite sides of the washer slits. Electrical leads for current bias and voltage measurements are arranged symmetrically with respect to the washers, which prevents interaction of the bias circuit with the input and modulation circuits.
According to one embodiment of the invention, there is provided a symmetrical SQUID apparatus comprising: (a) a substrate; (b) a first pair of identical superconductor washers symmetrically formed on the substrate to address each other in mirror-like configuration, each of the first pair of washers having a central opening and a slit extending therefrom to a washer edge at a central region of the apparatus; wherein said slits of the first pair of washers are commonly aligned; (c) a second pair of identical superconductor washers symmetrically formed on the substrate to address each other in mirror-like manner, each of the second pair of washers having a central opening and a slit extending therefrom to a washer edge at the central region; wherein the slits of the second pair of washers are commonly aligned and generally at right angles to the slits of the first pair of washers; (d) a pair of Josephson junctions symmetrically disposed in the central region on the substrate relative to the first and second pairs of washers; (e) superconductor connecting means on the substrate operatively connecting the first and second pairs of washers in series through the Josephson junctions, forming a series-connected SQUID loop; (f) bias lead means operatively connected with the Josephson junctions for biasing the junctions; (g) first input lead means operatively connected with the first pair of washers for providing input signals thereto; and (h) second input lead means operatively connected with the second pair of washers for providing modulation input signals thereto.
According to another aspect of the invention, a superconductor groundplane substantially operatively overlying the slits of the first and second pairs of washers is provided. Another aspect of the invention also provides for series-connected pairs of input coils configured to overlie and inductively couple with the first pair of washers for providing input signals thereto, and a second pair of series-connected coils configured to overlie and inductively couple with the second pair of washers for providing modulation or feedback signals thereto.
According to yet another aspect of the invention, the SQUID configuration is constructed using thin film technologies, wherein the superconductor materials are preferably Niobium. The components constructed by means of the film technology are symmetrically configured and electrically balanced so as to minimize coupling from modulation and bias signals to the SQUID loop and so as to minimize or cancel interference and coupling between components of the assembly. The film technology also provides for the formation of film shunt resistors across the Josephson junctions and for the formation of series resistor/capacitor shunt components for connection in parallel with the signal input coil portions of the system.
According to yet a further aspect of the invention, there is provided a symmetrical SQUID system, comprising: (a) first and second connected superconductor washers, forming a first SQUID washer pair; (b) third and fourth connected superconductor washers, forming a second SQUID washer pair; said second SQUID washer pair being identically shaped and being symmetrically and oppositely oriented relative to said first SQUID washer pair about a central region; (c) a pair of series-connected Josephson junctions in said central region, operatively symmetrically aligned relative to said first and said second SQUID washer pairs; (d) superconductor connecting means for operatively connecting said first and second SQUID washer pairs in series through said pair of Josephson junctions to form a series-connected SQUID loop; (e) first input circuit lead means symmetrically positioned relative to said first and second SQUID washer pairs for providing input signals thereto; and (f) output bias lead means operatively connected to said pair of Josephson junctions for biasing said junctions and for providing output signals from the SQUID system.
According to yet a further aspect of the invention, there is provided a method of configuring a SQUID circuit of the type having a pair of Josephson junctions, and input and modulation circuitry, for low-noise operation, comprising the steps of: (a) providing input circuit portions of the SQUID circuit with high inductance for matching arbitrary external circuits; (b) providing the SQUID circuit with a gradiometric configuration for desensitizing the SQUID circuit to uniform external ambient fields; (c) symmetrically configuring modulation and input coil portions of the SQUID circuit to minimize signal coupling therebetween; (d) routing signal flow paths for current bias and modulation signals of the SQUID circuit to prevent magnetic fields produced by signals flowing therethrough from coupling to the SQUID; and (e) electrically connecting the input and modulation secondary circuits of the SQUID in series with the Josephson junctions to minimize the rms current noise of the SQUID. The invention further includes the above method wherein parameters for the input and modulation circuit portions of the SQUID circuit are selected to define a well-defined resonance point for the SQUID within which low-noise operation is possible.
According to yet a further aspect of the invention, there is provided a method of configuring a method of configuring a SQUID circuit of the type having a pair of Josephson junctions, and input and modulation circuitry, for low-noise operation, comprising the steps of: (a) providing input circuit portions of the SQUID circuit with high inductance for matching arbitrary external circuits; (b) providing the SQUID circuit with a gradiometric configuration for desensitizing the SQUID circuit to uniform external ambient fields; (c) symmetrically configuring modulation and input coil portions of the SQUID circuit to minimize signal coupling therebetween; (d) routing signal flow paths for current bias and modulation signals of the SQUID circuit to prevent magnetic fields produced by signals flowing therethrough from coupling to the SQUID; and (e) selecting parameters for the input and modulation circuit portions of the SQUID circuit to define a well- defined resonance point for the SQUID within which low-noise operation is possible. The invention further contemplates the above method, wherein said resonance point is determined by the equation (1/2π) [L m (C/2)] L m is the sum of the inductances defined by the openings in the modulation washer portions and C is the Josephson junction capacitance.
While the preferred embodiment of the invention is described with reference to a thin film implementation using low-temperature superconductor materials, it will be appreciated by those skilled in the art that the invention is not limited to the low-temperature superconductor materials described, or even to low-temperature superconductors in general. Further, while the preferred embodiment of the invention is developed with respect to a particular film layout and its intended use in SQUID applications requiring low input current noise, it will be appreciated that as the end use applications for the invention vary, so will the specified design criteria for the symmetrical dc series-connected SQUID parameters. These and other aspects of the invention are only exemplary of embodiments of configurations, materials and/or design considerations used to implement structures that practice the broad principles of the invention. It will be understood that those skilled in the art may readily perceive yet other variations of the invention not specifically described above or in the following specification, but clearly included within the scope of the appended claims.
BRIEF DESCRIPTION OF THE DRAWING
Referring to the Drawing, wherein like numerals represent like parts throughout the several views:
FIG. 1 is a diagrammatic functional layout diagram in plan view of a thin film symmetric SQUID design configured according to the principles of this invention, illustrating those layers containing the SQUID loop inductance groundplane, and the series-connected washers and Josephson junctions of the device;
FIG. 2 is a diagrammatic functional layout diagram in plan view similar to that of FIG. 1, illustrating those layers containing the modulation and input coil portions of the device as they appear superimposed with the SQUID loop inductance portions of FIG. 1;
FIG. 3 is an electrical schematic diagram of the symmetrical SQUID network and transformer configurations illustrated in FIGS. 1 and 2;
FIG. 4 is a diagrammatic layout diagram in plan view of a preferred embodiment of a thin film symmetric SQUID chip configured according to the principles of this invention;
FIG. 5 is an enlarged fragmentary view of a portion of the thin film SQUID configuration of FIG. 4, illustrating one of the input washers in relation to the modulation or feedback washers;
FIG. 6 is an enlarged fragmentary view of the modulation or feedback washer portions of the thin film chip configuration of FIGS. 4 and 5;
FIG. 7 is a schematic diagram of a double-loop dc SQUID;
FIG. 8 illustrates a number of graphical comparisons between the series-connected dc SQUID configuration of this invention versus a parallel-connected dc SQUID configuration;
FIG. 8a shows the optimized input secondary inductances and corresponding washer hole widths as functions of the number of turns in the input coil;
FIG. 8b shows the variation of the parasitic capacitance as a function of the number of turns in the input coil;
FIG. 8c plots the optimized effective input inductance as a function of the number of turns in the input coil;
FIG. 8d plots the mutual inductance as a function of the number of turns of the input coil;
FIG. 8e plots the resonant frequencies of the input secondary washer, the input coil microstripline and the intended operating frequency as functions of the number of turns in the input coil for the series-connected configuration;
FIG. 8f plots the resonant frequencies of the input secondary washer, the input coil microstripline and the intended operating frequency as functions of the number of turns in the input coil for a parallel-connected configuration;
FIG. 8g plots the minimized equivalent current noise and the magnetic flux noise as functions of the number of turns of the input coil for both the series and parallel-connected configurations;
FIG. 8h plots the energy resolutions for both parasitic capacitance equal to zero and parasitic capacitance not equal to zero as functions of the number of turns of the input coil, for both the parallel and series configurations; and
FIG. 9 is a plot of optimized current noise, the resonant frequency of the input secondary washer, and the intended operating frequency as functions of the input secondary inductance for the series-connected configuration.
DETAILED DESCRIPTION OF THE INVENTION
This invention provides a dc SQUID device with input and modulation circuitry configured for high symmetry and low-noise operation, which provides an ideal building block for amplifiers, particularly those requiring high effective input inductance and very low equivalent current noise. The invention represents an improvement over the symmetrical dc SQUID apparatus disclosed in U.S. Pat. No. 5,053,834, the disclosures of which are herein incorporated by reference. As stated in the Background description, in order to be useful for a wide variety of applications, a dc SQUID with transformer coupling of the input and modulation signals must meet several general requirements, briefly summarized below.
(1) Inductance Matching. The SQUID input circuit should have a high inductance in order to satisfy inductance matching to arbitrary external circuits. A value of the order of 1 μH is typical.
(2) Insensitivity to Ambient Fields. The SQUID itself should be insensitive to ambient fields which may be present in the measurement environment. This is generally accomplished by surrounding the SQUID as much as possible by a superconducting shield, and by designing the SQUID with a gradiometric configuration. This is typically accomplished using two washers which may be connected in parallel (as in the Simmonds configuration) or in series (as in this invention) with the two Josephson junctions. In either case, such SQUID will have zero response to a uniform external field. The response to external field gradients will also be negligible if the separation between the holes in the two washers is small, as is typical.
(3) Negligible Coupling of the Modulation Signal to the Input Circuit. If the modulation and input coils are not sufficiently isolated, the modulation signal necessary for flux-locked loop operation may couple to the input circuit and interact with the load connected to the SQUID. This may distort the measured data. For this reason, the SQUID must be designed with negligible coupling of the modulation signal to the input circuit.
(4) Negligible Coupling of the Bias and Modulation Signals to the SQUID. The electrical connections to the SQUID for the current bias and modulation signals should be routed to prevent the magnetic fields arising from these signal currents from coupling to the SQUID. Substantial self-coupling may adversely affect proper operation of the SQUID.
(5) Low-Noise Performance. In order to successfully realize the extreme sensitivity of the dc SQUID, the SQUID design must take into account the adverse effects of the parasitic capacitance and the microwave resonances invariably present in integrated thin film transformer circuits. A commonly used figure of merit for dc SQUID performance is the rms magnetic flux noise. To achieve low flux noise, the SQUID inductance is usually made as small as possible, subject to the constraint that the SQUID input circuit be inductively matched to the anticipated load. For this reason, gradiometric SQUID designs have usually been configured with the SQUID washers in parallel with the Josephson junctions. The total inductance is then one-half the single washer inductance.
While the Simmonds configuration generally meets the five above requirements, it does not provide the desired performance for applications which require the detection of extremely weak currents. In particular, for such applications, the rms flux noise may not be the best figure of merit. A more relevant figure of merit is the equivalent rms current noise at the SQUID input. The rms current noise is given by S I 1/2 (f)=S.sub.Φ 1/2 (f)/M i , where S.sub.Φ 1/2 (f) is the rms flux noise of the SQUID and M i is the mutual inductance of the input coil and the SQUID inductance. To be useful for the widest possible range of applications, it is desirable not only to achieve the lowest possible flux noise, but also to design the SQUID input circuit to obtain the highest possible mutual inductance with respect to the SQUID.
The following analysis illustrates the desirability of the present invention's series configuration over a parallel configuration. A simple model wherein L x and n x (where x=s or p) denote the inductance per washer and the number of turns in the input coil coupled to each washer for the series and parallel configurations respectively can be used. Assuming that the coupling constant which describes the coupling of each input coil to its respective washer is unity, and that the slit inductances of each washer are negligible, the total inductances for the two configurations may be approximated as in Table 1 below.
TABLE 1______________________________________Inductance Comparisons forSeries and Parallel Washer ConfigurationsInductance Series Parallel______________________________________Total SQUID inductance 2L.sub.s L.sub.p /2Total input inductance 2n.sub.s .sup.2 L.sub.s 2n.sub.p .sup.2 LPTotal mutual inductance 2n.sub.s L.sub.s n.sub.p L.sub.p______________________________________
Assuming that it is desirable to match to the same load inductance and to have the same mutual inductance for both configurations, then
2n.sub.s.sup.2 L.sub.s =2n.sub.p.sup.2 L.sub.p
2n.sub.s L.sub.s =n.sub.p L.sub.p
and it follows that n p =n s /2 and L p =4L s . The total SQUID inductance turns out to be the same for both configurations. Therefore, if one ignores possible excess noise due to parasitic effects and microwave resonances, one would expect the flux noise of both configurations to be compatible. The parasitic capacitance in the parallel configuration, however, is likely to be as much as four times higher than in the series configuration. Excessive parasitic capacitance can degrade the performance of the SQUID. Also, the resonant frequency of the washers in the parallel configuration occurs at a much lower frequency because of the large size of the washers in that case. For a square washer with a square hole in the center, the inductance is given by 1.25 μ o d, where d is the side length of the hole. This means that the opening in each of the washers in the parallel configuration is four times larger than in the series configuration. Even though twice as many input coil turns are required in the series configuration, the much larger hole size required in the parallel configuration causes each washer to have a larger overall dimension. This can push the washer resonance dangerously close to the intended SQUID operating frequency. Furthermore, the large washer openings in the parallel configuration significantly increase the flux capture area of the SQUID. This means that large screening currents may be generated in response to uniform ambient fields. Such screening currents may lead to flux trapping in the Josephson junctions or otherwise compromise the operation of the SQUID. The flux capture area of the series configuration is much smaller, but more importantly, the screening currents completely cancel. Therefore, the series configuration may be less susceptible to flux trapping. Accordingly, the series configuration appears to have significant advantages over the parallel configuration.
Besides the series configuration distinction, the present invention utilizes a layout for the electrical connections made to the SQUID which reduces the number of contact pads required over prior art devices. The electrical leads to the modulation circuit and the SQUID body are arranged as two pairs of coplanar lines with the two "free" ends of each pair being connected to wire bond pads. Therefore, only four pads are required rather than the eight pads required by prior art parallel configurations. This feature not only simplifies assembly but improves reliability. As long as the separation between the two lines of each coplanar pair is small, the stray fields should be minimal, and self-coupling effects should be negligible.
With the above general design requirements and distinctions of the series configuration design over that of prior parallel configurations in mind, a better understanding of the present invention can be had with reference to FIGS. 1 and 2. Referring thereto, a preferred embodiment of the invention is "diagrammatically" illustrated. The diagrams of FIGS. 1 and 2 are not drawn to scale, and are not proportionately configured as they would be in an actual device, but are merely intended to facilitate an understanding of the relative orientations and interconnections between various physical and electrical portions of the inventive SQUID assembly. A diagrammatic plan view of the SQUID loop inductance "washer" layer and the series-connection Josephson junctions of the device and their respective interconnections, is generally illustrated in FIG. 1. Referring thereto, the material defining the four interconnected washer loops comprises a thin film layer of superconductor material. In the preferred embodiment hereinafter described in more detail, such layer comprises niobium. The layout configuration of the washer design is symmetrical or balanced, and includes first and second signal input washers 10 and 20 respectively of generally identical size and configuration. The input washers 10 and 20 respectively define aligned slots 11 and 21 respectively extending from cooperatively facing edges of the washers 10 and 20 and inwardly to central openings or holes 12 and 22 respectively of the washers 10 and 20. The washers 10 and 20 with their slots and central openings respectively form single turn secondaries for the two signal input transformers of the SQUID, as hereinafter described in more detail. The first and second input washers 10 and 20 are interconnected in part by means of a coplanar strip of superconductor material 30 patterned from the same film used to define the input washers.
Third and fourth washer members 15 and 25 respectively lying coplanar with and configured from the same superconducting material as the signal input washers 10 and 20, define the single turn secondaries for the modulation or feedback transformer coils of the system. The modulation washers 15 and 25 are symmetrically disposed between the first and second washers 10 and 20 and respectively define aligned slots 16 and 26 respectively originating from outer facing edges of the washers 15 and 25 and extending inwardly to central openings 17 and 27 respectively of the third and fourth washers 15 and 25. As was the case for washers 10 and 20, washers 15 and 25 are identical mirror images of one another and are symmetrically configured with respect to one another and with respect to washers 10 and 20. The aligned slots 16 and 26 of the third and fourth washers 15 and 25 respectively are oriented generally at right angles to the aligned slots 11 and 21 of the signal input washers 10 and 20 respectively. The washers 20 and 15 are electrically connected by means of a superconductor strip of material 31, and the washers 25 and 10 are electrically connected by means of a superconductor strip of material 32. The four washers 10, 15, 20 and 25 and their interconnecting strips 30, 31 and 32 are commonly formed by a niobium superconductor film deposited over other thin film layers on a common substrate in a manner well-known in the art and described below with respect to a preferred embodiment of this invention.
A groundplane of superconductor material, generally indicated at 40 is configured to underlie the four washer slots 11, 16, 21 and 26 and is electrically insulated from the superconductor material forming the washers by an insulative layer (not illustrated), except for those areas designated at 42 and 44 which define first and second Josephson junctions of the SQUID assembly. The Josephson junctions extend from the groundplane superconductor and through the insulative layer and make electrical contact with the superconductor material of the third and fourth washers 15 and 25 respectively. Other thin film patterns of the superconductor material used to define the groundplane form interconnecting conductive links and conductive lead paths (to be hereinafter described in more detail) for the input and modulation coil portions of the SQUID assembly.
A pair of bias conductors 29 and 41 provide electrical signal bias connections to the washer and Josephson junction assembly. The bias leads 29 and 41 extend closely adjacent to one another from bonding pads 50 and 51 respectively and to the SQUID assembly. The bias lead 29 is commonly formed from the thin film material comprising the washers and is electrically connected to the interconnecting strip 30. The second bias conductor 41 is formed from the superconductor material of the groundplane, and is electrically connected with the groundplane 40. Additional layers of deposited insulator and resistive materials form part of an actual thin film device, as will be hereinafter described in more detail, but for simplicity, are not illustrated in FIGS. 1 and 2.
The "coil" layer is diagrammatically illustrated in FIG. 2, showing the coils as they conceptually align with the washer and interconnect portions of the SQUID configuration previously described in FIG. 1. The washer outlines are illustrated in phantom in FIG. 2. In the preferred embodiment, as hereinafter described, the coil layer is actually deposited first on the substrate and underlies the later deposited washer material. Referring to FIG. 2, first and second primary signal input coils 60 and 61 are spirally wound to cooperatively underlie and align with the first and second washers 10 and 20 respectively. Third and fourth coils 62 and 63, defining the primary modulation or feedback coil windings are cooperatively spirally wound in relation to the third and fourth washers 15 and 25 respectively. The coils 60, 61, 62 and 63 are commonly formed from a thin film superconductor material, as hereinafter described. The inwardly wound ends respectively of the first and second signal input coils 60 and 61 are physically and electrically interconnected by means of a superconductor link 45. The outer ends of the first and second primary signal coils 60 and 61 are extended to form lead lines 64 and 65 respectively extending to a pair of signal input pads 52 and 53. The inwardly wound ends of the primary modulation coils 62 and 63 are electrically connected by means of a superconductor link formed of segments 46, 47 and 66. The outer ends of the modulation coil windings 62 and 63 extend to form lead lines 67 and 68 which extend to feedback or modulation bonding pads 54 and 55 respectively. In the preferred embodiment, the interconnecting links 45, 46 and 47 are formed from the same superconductor material used to define the groundplane 40. The interconnecting link 66 as well as the lead lines 64-68 are deposited at the same time and are formed from the same material as the coils 60-63. In the preferred embodiment, the separation between any two lead lines of a coplanar pair (such as leads 29, 41 and leads 67, 68) is small, such that stray fields are minimal and self-coupling effects are negligible. In FIGS. 1 and 2, the solid circular areas denote vias or interconnecting links between physical layers of the structure.
An electrical schematic diagram of the symmetrical SQUID assembly diagrammed in FIGS. 1 and 2 is illustrated in FIG. 3. The FIG. 3 schematic diagram also includes resistive and capacitive elements that form a part of the preferred embodiment thin film device, illustrated in more detail in FIGS. 4-6. Referring thereto, it will be appreciated that the Josephson junctions 42 and 44 are operatively connected in series through the secondary feedback and input coils represented by the washers 15, 20, 10 and 25. The "FIG. 8" series connection can be traced from input bias pad 50, through bias lead 29, connector link 30, secondary input coil/washer 20, connector link. 31, secondary feedback coil/washer 15, Josephson junction 42, groundplane conductor 40, Josephson junction 44, secondary feedback coil/washer 25, connecting link 32, secondary input coil/washer 10, and back to the connector link 30. Bias pad 51 is connected by means of the lead line 41 to both of the Josephson junctions 42 and 44 through the groundplane conductor 40. The input primary coils 60 and 61 are also connected in series between the input signal pads 52 and 53. Similarly, the feedback or modulation input coils 63 and 62 are connected in series between the feedback or modulation pads 54 and 55. Accordingly, only a single pair of bonding pads or terminals are required to energize each of the signal input and feedback transformers, and only a single pair of bias terminals are required to bias the SQUID inductance loop. Such pad reduction provides a significant improvement in simplicity and reliability over prior art parallel connected symmetrical SQUID configurations such as that of Simmonds.
Microwave resonances of the input circuit are damped in a nearly noise-free manner by the insertion of a series R x C x shunt across the input coils (as hereinafter discussed in more detail). The R x C x shunt components for the input coil 60 are illustrated in FIG. 3 at 70 and 71 respectively, and the R x C x shunt components associated with the input coil 61 are illustrated at 72 and 73 respectively. Josephson junction 42 is illustrated in FIG. 3 as having a shunt resistor 74 and a capacitance 75 associated therewith. Similarly, Josephson junction 44 has a shunt resistance 76 and a capacitance 77 associated therewith. The parasitic capacitance associated with the input washer 10 is indicated at 78, and the parasitic capacitance associated with the input washer 20 is indicated at 79.
While the diagrammatic illustrations of FIGS. 1 and 2 enable the invention to be operatively described, they do not represent a scaled representation of the invention. A preferred embodiment of a thin film network or chip incorporating the symmetric design principles previously described with respect to FIGS. 1-3 is illustrated in more detail in FIGS. 4-6. FIGS. 4-6 are intended to illustrate the various film components of the assembly as they would proportionately appear relative to one another, but those skilled in the art will realize that the limitations inherent in patent drawings make the FIGS. 4-6 illustrations resolution, at best, approximations of the actual physical layouts.
A composite view of the entire thin film circuit or chip of the preferred embodiment as formed on a monolithic substrate is illustrated in FIG. 4. In the preferred embodiment, a plurality of the dc SQUID circuits are deposited on a 4 inch Si wafer having a thermally grown oxide layer. The symmetrical SQUID chip size of a single circuit, as illustrated at 80 in FIG. 4 is approximately 3 mm by 5 mm. In order to provide consistency with the diagrammatic layouts previously described with respect to FIGS. 1-3, the actual thin film implementation thereof, as illustrated in FIGS. 4-6, use the same numerical designations of the FIG. 1-3 diagrams. As illustrated in FIG. 4, when physically implemented in a functional circuit, the signal input washers 10 and 20 are significantly larger than the modulation or feedback washers 15 and 25. Due to drafting limitations, details of the modulation washer portions of the device have not been illustrated in any detail in FIG. 4. More detail thereof is shown in FIG. 6. In the physical implementation of the invention, it will be noted that the six bonding pads, suitable for standard nail-head bonding connection as well as pressure contacts using spring-loaded contact pins, occupy most of the space on the deposited dc SQUID chip. The FIGS. 4-6 implementation of the preferred embodiment also illustrates the two deposited R x C x shunt resistors and capacitors of FIG. 3, namely 70,71 and 72,73 (see FIGS. 4 and 5) and the deposited Josephson junction shunt resistors 74 and 76 (best illustrated in FIG. 6).
An enlarged view of the signal input washer 10 portion of the symmetrical SQUID assembly of FIG. 4 is illustrated in FIG. 5. FIG. 5 better illustrates the relative size differential between the input signal washers 20 and 10 and the modulation or feedback washers 25 and 15. FIG. 5 also illustrates the close spacing and symmetrical orientation of the lead line pairs such as 29,41 and 67,68. Also illustrated, in fragmented view by partial removal of the overlying washer 20 material is a portion of the input coil winding 61 shown as connected to the lead lines 65 and 45. The degree of groundplane 40 overlap with the slot 21 of washer 20 is also apparent. A further enlarged view of the modulation coil and washer portions 15 and 25 of the symmetrical SQUID assembly of FIGS. 4 and 5 is shown in FIG. 6. FIG. 6 illustrates the symmetrical orientation of the components and their lead lines, the extent of the groundplane 40, the Josephson junctions 42 and 44. Modulation coils 62 and 63 are shown connected in series between lead lines 67 and 68 by means of the connecting links 46,66 and 47. It is noted that link 66 and the lead line 68 underlie the groundplane 40. FIG. 6 also best illustrates the deposited shunt resistors 74 and 76 for Josephson junction 42 and 44 respectively, and the overall symmetry of the film layout.
The preferred process sequence used to fabricate the thin film symmetrical SQUID chip of the preferred embodiment illustrated has been selected to be generally consistent with previous designs for ultralow-noise SQUIDs, and consistent with currently available process technology. A Nb film (150 nm thick) is sputter deposited onto a Si wafer having a thermally grown oxide layer. The first Nb film is patterned using a wet etchant to define the input coils 60, 61, 62 and 63 and contact pads 50-55 of the network. While only a portion of the input coil 61 is illustrated in FIG. 5, and the modulation coils 62 and 63 are illustrated as dashed lines in FIG. 6, it will be appreciated that the input and modulation coils underlie the washer conductors, as previously described with respect to FIGS. 1-3. The linewidths and pitch of the input (60, 61) and feedback (62, 63) coils are 3 μm and 6 μm respectively. The wet etchant provides nicely tapered edges which are essential to prevent shorts to subsequent layers, and minimizes sensitivity to electrostatic discharge. A 150 nm thick PECVD SiO 2 insulation layer is next deposited over the coil patterns. The insulation layer can be deposited at elevated temperatures to ensure that a low dielectric constant is obtained. Contact vias to the coils are etched through the SiO 2 using buffered HF. Next, a trilayer of Nb/Al--AlO x /Nb is deposited and patterned using RIE. In depositing the trilayer, a 200 nm Nb layer is first deposited and immediately followed by a thin (50 nm) Al layer. The Al is then exposed to pure oxygen to form the tunnel barrier. The dependence of the junction critical current density (J c ) on the oxidation conditions is predetermined (as hereinafter described) so that the conditions necessary to obtain the design value of J c =90A/cm 2 are known. After oxidizing the Al, a thin 30 nm layer of Nb is deposited to complete the trilayer. The trilayer forms not only the Josephson junctions, but also the groundplane 40 for the washer slits, the conductive path between the Josephson junctions in the series circuit, the current return path 45 for the input coil, the current return path links 46 and 47 for the primaries of the input modulation coils and the lower electrodes of the capacitors 71 and 73. The upper Nb layer of the trilayer is then anodized to isolate the Josephson junctions and define high critical current contacts to the lower Nb layer of the trilayer. The anodized Nb 2 O 5 layer is approximately 100 nm thick and defines the capacitor dielectric layers. The anodization is most easily carried out using a resist mask. The Josephson junctions 42 and 44 for the SQUID configuration are nominally 3×3 μm 2 . With corner-rounding, the actual junction area and capacitance are estimated to be A=5.5 μm 2 and C=0.45pF, respectively.
After the anodization step, a second 150 nm blanket layer PECVD SiO 2 is deposited at a reduced temperature, and contact vias are opened as before, to expose the junctions and contacts to the base electrode, capacitors, and pads. The reduced temperature is necessary to avoid deterioration of the Josephson junctions. However, it has been found that a high-quality oxide with a reasonable dielectric constant and minimal pinhole density can be deposited in this way. Next, a thin (25 nm) Pd resistor layer is sputter deposited and patterned using lift-off methods which can be done with negligible film tearing if the resist stencil is properly prepared. The Pd defines the shunt resistors of the FIG. 3 circuit in order to ensure that the SQUID will be operable for temperatures of T<<4.2K. The Pd also protects the pads from corroding in air. The final Nb layer (350 nm thick) is then deposited and patterned using RIE, to define the washers, the top electrodes of the capacitors, and interconnects, as previously described. To complete the wafer, a 200 nm SiO 2 passivation layer is deposited, and vias to the contact pads are opened.
Design Optimization
The symmetrical series-connected SQUID configuration of this invention is particularly applicable to the design of a dc SQUID with low equivalent input current noise. The following overview of some of the desired design features of such a SQUID will assist in understanding the detailed optimization criteria for the SQUID configuration. The optimization has been carried out for designs which minimize the SQUID responsivity to ambient magnetic fields. Since these ambient fields are usually due to distant sources they generally can be considered to be uniform over a length scale of the order of the outer dimension of the SQUID. For the low-noise SQUID, for example, a two-hole geometry, consisting of two washers connected either in series or in parallel, therefore offers a high degree of selectivity against ambient fields. The parasitic capacitance introduced in a series configuration, however, is likely to be significantly lower than that introduced in a parallel configuration. Perhaps more significantly, even though a perfectly balanced parallel configuration exhibits zero response to a uniform applied field, a substantial screening current in the SQUID loops can still be induced. Conceivably, this screening current may lead to flux trapping in the SQUID or junctions, resulting in significantly reduced performance. In the series configuration of this invention, the response to a uniform field is also zero, but the screening currents cancel as well. Further, performance projections confirm that there is little loss in sensitivity with the series configuration.
In order to operate a SQUID in a flux-locked mode, feedback must be applied to the SQUID. If the feedback circuit is not properly designed, however, the feedback circuit may significantly couple to the input circuit. It is possible to greatly reduce this effect by using separate secondaries to couple the input and feedback signals to the SQUID. The total inductance of the SQUID, L, is then the sum of two parts: L=L s ,i +L s ,f where L s ,i +L s ,f are the inductances of the input and feedback secondaries, respectively. In order to preserve the symmetry and minimize cross-coupling, two pairs of secondary loops are used, and the two pairs are arranged at right angles to each other. This is diagrammatically shown in FIGS. 1 and 2 and in FIGS. 4-6. In principle, the Josephson junctions may be connected in parallel or in series with the secondaries. The reduced parasitic capacitance of the series configuration is an advantage, however, and it has been found that it is difficult to prevent the washer resonance in a parallel configuration from moving too close and interfering with the intended operating frequency of the SQUID. This is shown in more detail below. Thus, for conventional operation, the series configuration is preferable.
The functional form that is minimized in a design optimization is an application specific parameter. Methods of SQUID design optimization are well-known in the art. Those not knowledgeable are referred to J. Knuutila, et al., "Design, Optimization, and Construction of a DC SQUID with Complete Flux Transformer Circuits," J. Low Temp. Phys. 71: 369-392 (1988). For magnetometer or gradiometer applications, for example, it is generally more desirable to minimize the magnetic field or field gradient noise, respectively, rather than the energy resolution. The minimized field noise does not necessarily coincide with either the minimum of the energy resolution or the magnetic flux noise. Fortunately, the minima of the energy resolution and noise functions are rather broad, making it possible to optimize one performance parameter without significantly degrading the others. Since a low current noise is generally required for many applications, the energy resolution is not necessarily the appropriate figure of merit for these devices. Rather, it is desirable to minimize the equivalent input current noise S I 1/2 (f), which is given by ##EQU1## where L is the total SQUID inductance; M i is the mutual inductance of the input coil L i and the input secondary; and ε p is the energy resolution which takes into account the parasitic capacitance, which may be written as ##EQU2## γ where is a constant which depends on design dependent parameters only. From Eq. (1) it is clear that optimum performance requires a SQUID with low flux noise and an input circuit with high mutual inductance. It is noted that both of these quantities depend on the same parameters and therefore cannot be optimized separately. Eq. (1) is the functional form used to carry out the design optimization of the SQUID.
The input and feedback coils and their secondaries must be designed by taking into account possible microwave resonances. It has been shown previously that the resonant properties of two washers connected in series or in parallel are determined solely by the design of the individual washers. This means that there is little interaction between the washers as far as the stripline and washer resonances are concerned, so the input and feedback circuits can be designed separately. The inductance of the feedback secondary should be a small fraction of the total SQUID inductance, yet large enough so that the mutual inductance of the feedback coil and secondary, M f , is sufficient to ensure that the feedback current ΔI f /Φ o is roughly in the range 1-10 μAΦ o . This is necessary to further prevent feedback current from coupling through to the load and to provide sufficient feedback dynamic range.
Because of the separate input and feedback circuits, the symmetric SQUID shown in FIG. 3 is essentially a double-loop (FIG. 7) device. For the symmetric SQUID, the inductance of the feedback secondary may be viewed as a parasitic inductance, since it is small and not part of the input coupling circuit. Then, at high frequencies, the high parasitic capacitance of the input secondary is essentially a short, leading to a resonance at a frequency f r =(1/2)(L s ,f (C/2)) -1/2 . Inside this high frequency resonance, the SQUID characteristics are very smooth, and the energy resolution is nearly the same as that for a SQUID having the same total inductance but with Cp=O. This additional,high-frequency mode of operation may in principle be realized with either the series or parallel configurations, although the effects of the potentially very high parasitic capacitance of the parallel configuration are unclear.
In order to more easily compare the FIG. 3 symmetrical circuit with the design criteria, the following equivalence chart can be applied to the FIG. 3 circuit:
TABLE 2______________________________________FIG. 3 Circuit Component EquivalentsNumber on FIG. 3Terminology Component Design______________________________________10, 20 input/washer L.sub.s,i /215, 25 feedback/washer L.sub.s,f /242, 44 Josephson junction JJ60, 61 input coil L.sub.i /262, 63 feedback coil L.sub.f /270, 72 RC shunt resistor 2R.sub.x71, 73 RC shunt capacitor C.sub.x /274, 76 junction shunt R resistor75, 77 junction capacitance C78, 79 parasitic capacitance 2C.sub.p______________________________________
We can now discuss the optimization of the symmetrical series-connected SQUID configuration of the preferred embodiment, in detail. In order to be useful for a broad range of experiments, a load inductance of 1 μm has been assumed. As discussed above, a gradiometric washer configuration is preferred in order to minimize sensitivity to external signals. Optimizations of the input circuit have been carried out for both the series and parallel configurations by minimizing the equivalent input current noise S I 1/2 (f). Generally, an overlap of 25 μm per side was used.
FIG. 8 illustrates a number of comparative plots for the series-connected dc SQUID configuration of this invention versus that a parallel-connected configuration. The optimized input secondary inductances L s ,i (filled symbols) and corresponding washer hole widths d (open symbols) are shown in FIG. 8a as functions of the number of turns N in the input coil. Similarly, the variation of the parasitic capacitance C p is shown in FIG. 8b as a ratio of the parasitic capacitance to the junction capacitance (C p /C), as a function of the number of turns in the input coil. Because of the saturation effect of the energy resolution for large C p , the input secondary inductances of the two configurations are not significantly different, even though the parasitic capacitance differs substantially. For the series configuration, however, the width of the washer hole is significantly smaller. The large size of the parallel configured washers will cause this design to be much more sensitive to the formation of large screening currents and possibly to increased flux trapping. For the series configuration, as long as the SQUID is well balanced, these screening currents cancel.
The optimized effective input inductance L i ,eff (which takes into account the screening effect of the input secondary inductance) and the mutual inductance M i are shown over the same range of N in FIGS. 8c and 8d, respectively. Matching to a 1 μH load inductance requires input coil designs with 23 and 45 turns for the parallel and series configurations, respectively, with corresponding mutual inductances of 24 nH and 25 nH, respectively. Since the secondary inductances are not significantly different, the input coil of the parallel configuration requires far fewer turns. This may seem to be advantageous, but it is necessary to examine the behavior of the microwave resonances. The fundamental of the stripline resonance at frequency f s is calculated from the total length of the input coil. In the preferred embodiment the input and feedback coils have been designed to be floating, so the total length corresponds to λ/2 in both cases. The washer resonance at frequency f w is calculated using a previously developed equivalent circuit model of the coupled SQUID. According to simulations, the frequency f op corresponding to the optimal point of operation is given by f op =0.3f J , where the Josephson frequency f J =I c R/Φ O . These frequencies are plotted as functions of N in FIGS. 8e and 8f. The resonant frequencies of the input secondary washer are plotted as diamonds, those of the input coil microstripline as triangles, and those for the intended operating frequency as circles. Previous results suggest that it is necessary to maintain roughly a factor of 4 difference between the intended operating frequency and the stripline and washer resonant frequencies; that is, 4f s <f op <f w /4. Because of the large number of turns required to match the load inductance, f op >>f s for both configurations, but in the parallel configuration the washer resonance is dangerously close to the intended operating frequency of the SQUID. This is another drawback of the parallel design.
The minimized equivalent current noise S I 1/2 (f) and magnetic flux noise S.sub.Φ 1/2 (f) are shown in FIG. 8g as functions of the number of turns N in the input coil. The minimized equivalent current noise is illustrated by filled symbols, and the magnetic flux noise is indicated by open symbols. The current noise improves steadily as N increases because of the increasing mutual inductance; for the values of N required to satisfy inductance matching to the load, however, the current noise of the parallel and series configurations are nearly the same, being 300fA/√Hz and 310fA/√Hz, respectively. The flux noise is also comparable, with broad minima of 3.4 μΦ O /√Hz and 3.8 μΦ O /√Hz around N=26 and N=43 for the parallel and series configurations, respectively. The energy resolutions ε p and ε are shown in FIG. 8h as a function of the number of turns of the input coil. The energy resolution ε p where C p ≠O, is indicated by filled symbols. The energy resolution ε, where C p =O, is indicated by open symbols. The energy resolutions ε p calculated with the effect of parasitic capacitance taken into account exhibit broad minima of 461 and 501 around N=25 and N=38 for the parallel and series configurations, respectively. The minima are broad and close to but not coincident with the flux noise minima. In terms of noise performance, the parallel and series configurations are therefore seen to be comparable. The energy resolution ε determined from separate optimizations carried out neglecting the parasitic capacitance (i.e., for C p =0) is roughly a factor of √5 lower, as expected. This suggests that a reasonable performance enhancement may be achieved for operation inside the high-frequency double-loop resonance. In particular, for the value of N required to satisfy inductance matching, the current noise is about 200fA√Hz for both configurations for operation inside the high-frequency resonance. To be successful, this requires that the feedback circuit be properly designed.
Summarizing the above results, it can be appreciated that the series-connected configuration is preferable for a number of reasons. One possible concern is that the minimization of the equivalent current noise necessarily leads to a rather high input secondary inductance and hence total SQUID inductance. Low-noise, high inductance (˜400 pH) SQUIDs have been made previously, but the inductance necessary for a low-noise SQUID implied by the results in FIGS. 8a and 8b is much higher. For this reason, it is of interest to carry out optimizations for fixed inductance of the input secondary. This has been done for the series configuration and the results are summarized in FIG. 9. FIG. 9 plots the optimized current noise (circles), the resonant frequency of the input secondary washer (diamonds), and the intended operating frequency (squares) as functions of the input secondary inductance. The optimizations have been carried out subject to the constraint of inductance matching to a 1 μH load. The number N of input coil turns required for each SQUID inductance is indicated. FIG. 9 shows that the current noise improves steadily as the inductance of the input secondary is reduced. The current noise values plotted are determined subject to the constraint of inductance matching to the 1 μH load. For this reason, the number of turns N in the input coil varies considerably, becoming very large as the secondary inductance is reduced. The respective values of N are shown in the figure. In order to accommodate an increasing number of turns in the input coil, the secondary washer must be made larger, thereby pushing the washer resonance to lower frequencies. At the same time, the intended operating frequency of the SQUID is pushed to higher frequencies as the SQUID inductance is reduced, owing to the increased critical current. These frequencies are seen to approach each other roughly for L s ,i <500 pH. Therefore a more conservative value L s ,i ˜500 pH is used for the input secondary. Choosing a hole width d=140 μm for the input secondary washers, for example, gives L s ,i =465 pH. Then, the inductance matching condition requires that N=50 turns be used for the input coil. It is shown below that the lower input secondary inductance used does not lead to any significant increase in the minimum current noise.
The microwave resonances of the input circuit are damped by the insertion of a series R x C x shunt across the input coils, as previously discussed and shown in FIG. 3. The resistance R x is matched to the nominal impedance of the microstripline (16.3 Ω) and properly terminates the "open" end as the stripline leaves the washer. The capacitances C x fixes the resonant frequency of the input circuit. Choosing C x =100 pF fixes the input circuit resonance at 42 MHz. The Q-value of the resonance, Q=2.7, ensures that the resonance is well damped, but not over-damped to prevent the Josephson oscillations from mixing noise down to low frequencies. Further damping may be provided by an optional damping resistor R p placed across each of the input secondary washers.
The feedback circuit must be designed so that the inductance of the feedback secondary L s ,f is much smaller than the inductance of the input secondary L s ,i. In addition, the mutual inductance M f of the feedback coil L f and the feedback secondary must be sufficient to ensure that the feedback current ΔI f /Φ O is roughly in the range 1-10 μA/Φ O . This is necessary in order to prevent excessive current from coupling through to the load. It is estimated that the feedback current is given by ##EQU3## where L s ,i.sup.(dc) is the screened inductance of the input secondary. These requirements must be met subject to the usual conditions on the microwave resonances discussed previously. We start by choosing a hole width of d=10 μm for the feedback secondary washers, which gives L s ,f =37 pH. Then, for L s ,i =465 pH, the total SQUID inductance L=502 pH and L/L s ,f =13.6. Using N=3 turns for each of the feedback coils, L f =360 pH and M f =100 pH. According to Eq. (16), ΔI f ≈3 μA, which is in the required range. Because of the small number of turns in the feedback coil, the stripline resonant frequency f s =126 GHz and the washer resonant frequency f w =142 GHz are both significantly higher than the range of SQUID operating frequencies. Similarly, the small parasitic capacitance (30fF) across the small feedback secondary inductance ensures that the feedback circuit resonance is also pushed to high frequencies. Thus, damping circuits for the feedback circuit are not necessary. For operation inside the high frequency resonance referred to earlier, f r =(1/2)(L s ,f (C/2)) -1/2 =55 GHz. This frequency is much higher than the microwave resonant frequencies of the input circuit, yet much lower than the resonant frequencies of the feedback circuit. Thus, this choice of design parameters for the feedback circuit should allow proper operation at a well-defined point in the conventional low frequency range or in the additional high frequency range arising from the double-loop SQUID geometry. Having determined the design parameters of the feedback circuit, the expected performance parameters of the SQUID are recalculated using the expression for the current noise in Eq. (1). Optimizing the critical current density for the fixed inductance L=502 pH and β c =0.7, the critical current I c =5 μA and the shunt resistance R=10Ω per junction are determined. The screened inductance parameter β dc =2L dc I c /Φ O =1.2, where L dc is the screened SQUID inductance, so the maximum peak-to-peak current swing is roughly ΔI m ≈5 μA. The equivalent current noise of the series configured input SQUID S I 1/2 (f)=310fA/√Hz, so that no degradation of the noise performance occurs because of the lower SQUID inductance chosen. This is a consequence of the wide breadth of the noise minimum. It is not advisable to further reduce the SQUID inductance (to reduce the flux noise, for example) because then the inductance matching condition requires that more turns be added to the input coils, causing the input secondary washer resonance to move too close to the intended operating frequency. The calculated flux noise S.sub.Φ 1/2 (f)=3.3μΦ O /√Hz and the energy resolution ε p =450. The flux noise at 1 Hz, and hence the low frequency current noise as well, are expected to be comparable to the white noise values given. The full set of design and performance parameters of the dc series-connected input SQUID configuration of the preferred embodiment as designed for use as a low-noise input stage of an amplifier are summarized in Table 3 below.
TABLE 3______________________________________Series-Connected dc SQUID Design andCalculated Performance Parameters for T = 4.2K VALUE______________________________________INPUT CIRCUIT PARAMETERInput secondary L.sub.s,i 465 pHInput coil turns N 50Eff. input ind. L.sub.i,eff 1 μHMutual inductance M.sub.i 23 nHCoupling constant k.sub.i 0.99Parasitic capacitance C.sub.p 3.5 pFStripline resonance f.sub.s 0.6 GHzWasher resonance f.sub.w 28 GHzShunt resistance R.sub.x 16.3 ΩShunt capacitance C.sub.x 100 pFFEEDBACK CIRCUIT PARAMETERFeedback secondary L.sub.s,f 37 pHFeedback coil turns N 3Feedback loop ind. L.sub.f 360 pHMutual inductance M.sub.f 100 pHCoupling constant k.sub.f 0.88Parasitic capacitance C.sub.p 0.03 pFStripline resonance f.sub.s 63 GHzWasher resonance f.sub.w 128 GHzSQUID PARAMETERInductance 502 pHScreened inductance L.sub.dc 262 pHCritical current I.sub.c 5 μAJunction resistance R 10 ΩJunction capacitance C 0.45 pFJunction Area A 5.5 μm.sup.2β = 2 LI.sub.c /Φ.sub.0 2.4β.sub.dc = 2 L.sub.dc I.sub.c /Φ.sub.0 1.2β.sub.c = 2 πI.sub.c R.sup.2 C/Φ.sub.0 0.7f.sub.op = 0.3 I.sub.c R/Φ.sub.0 7 GHzCurrent noise S.sub.I .sup.1/2 (f) 310 fA/√HzFlux noise S.sub.Φ .sup.1/2 (f) 3.3 μΦ.sub.0 /√HzEnergy resolution ε.sub.p 450 h______________________________________
From the foregoing, it will be appreciated that the series-connected symmetrical dc SQUID configuration described offers significant advantages over the prior parallel configurations. While the present invention has been described with respect to its application as a SQUID with low equivalent input current noise, and with regard to a preferred low-temperature thin film superconductor implementation, it will be understood that the invention is not intended to be limited to the specifics of the described preferred embodiments. A variety of applications for the SQUID are possible, including use in amplifiers, magnetometers, gradiometers and susceptometers. The invention may also be adapted for high-temperature thin film superconductors. Such descriptions are intended to provide specific examples of embodiments which clearly describe and disclose the present invention. Accordingly, the invention is not limited to such described embodiments, or to the use of specific components, configurations or materials described therein, other than as defined by the claims herein. All alternative modifications and variations of the invention which fall within the broad scope of the appended claims are covered. | A multiple loop dc SQUID configuration with input and modulation circuitry configured for high-symmetry and low-noise operation is disclosed. The configuration is adaptable to implementation using standard thin film circuit fabrication technology. The SQUID inductance is defined by a plurality of washer-shaped thin superconducting films symmetrically oriented on a substrate and connected in series through a pair of Josephson junctions to form a multiple-washer gradiometric structure. The series connection arrangement also minimizes the number of required input and output terminal pads. Bias and modulation conductors are configured so as to prevent magnetic fields produced by currents flowing therethrough from coupling to the SQUID, and the modulation and input coil portions of the SQUID circuit are symmetrically configured to minimize signal coupling therebetween. A method of parameter selection for the input and modulation circuit portions of the SQUID configuration is disclosed which establishes a well-defined resonance point for the SQUID, within which low-noise operation is possible. | 74,745 |
RELATED APPLICATIONS
[0001] This application is a division of U.S. application Ser. No. 09/300,992 filed Apr. 28, 1999.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to information cards generally, and more specifically to a card having a plurality of separable elements or features, such as an embroidered patch and a heat transfer, that may each be removed from such card and applied to a consumer article either independently of, or in conjunction with each other.
[0004] 2. Preliminary Discussion
[0005] Keepsakes, memorabilia, souvenirs and the like serve important and useful functions in our society. Not only do they convey information and memorabilia concerning a particular experience, but they allow an individual to take and share such experience with their friends and family.
[0006] For example, an individual who visits a city attraction, such as a zoo or the like, for the first time might purchase a hat adorned with the individual's favorite animal and the name of the zoo. In this example, the markings on such hat, and more particularly the name of the zoo, transform the function of the hat from one of complete utility to an ongoing remembrance of the individual's visit. Such markings also serve an important marketing purpose with respect to the direct purchaser, but they also serve as a general marketing medium, i.e. it is anticipated that others seeing the source indicator might also desire to visit or frequent such source.
[0007] In general, whether a business is a pure “tourist trap,” such as Disney World® or the Statue of Liberty, or whether a business is a tourist trap by virtue of its placement in a particular city or location, such as the Washington Monument and the Smithsonian Museum, or whether the business is a purely local concern trying to attract customers, such as the sandwich shop down the street, the more people that frequent a particular location, the greater the benefit to the target business and the local economy. Consequently, businesses spend huge sums trying to attract customers or patrons to frequent their establishments.
[0008] Once customers or patrons are “through the doors” so to speak, they are immediately enticed to spend money. Everyone knows that tourists, in particular, don't like to go away empty handed. But even more importantly, tourists like to purchase items that have lasting value. For example, a photograph, magnet, button or an informational booklet describing or displaying a particular experience has lasting value, and can usually be enjoyed by future generations. An article of clothing displaying an aspect of a particular memorable experience tends to have a lesser amount of lasting value, since clothing tends to wear out with age and excessive use, but does in fact have great exhibition value, especially when it is important for the owner to convey that he or she has taken part in a particular experience. Patrons of rock concerts, professional sports games and plays that purchase licensed or sanctioned or authorized clothing items are perfect examples, and are also usually walking advertisements for such events, while university and college attendees and parents of the same frequently will wear items adorned with their college name or logo to show their school spirit or pride in being connected with such an institution.
[0009] Memorabilia usually come in one of two forms. The most popular type of memorabilia is the utilitarian or functional type, such as a shirt, button, magnet or the like. These items provide the patron with instant, expressive gratification as discussed above. The other type of memorabilia is the non-utilitarian or non-functional type, such as a booklet of information about a particular experience. Souvenir-type items in the form of booklets or other sources of audio, visual or literary-type information tend to have lasting value to the purchaser, and are usually intended to serve as a more complete reference commemorating a particular experience.
[0010] It is rare, however, that prospective patrons or customers are provided with the ability to purchase an item or souvenir that is both functional and non-functional as described above. The item of the present invention is a unique product designed to convey information about a particular topic, i.e. in the form of a non-functional card-type medium, along with the provision of a plurality of functional keepsakes related to such topic and integrated into such product. The functional articles provided along with the information card may be separated from the information card and applied to another object to create an additional keepsake incorporating such functional articles. More specifically, the assembly of the present invention is comprised of an informational card having a first article, preferably a patch, embroidered emblem or the like, removably attached thereto and capable of being applied to a separate object, and a second article, preferably an adhesively applied heat transfer, removably attached thereto and capable of being applied to the same separate object either independently of, or in conjunction with the first removable article. Both removable articles bear indicia that are preferably related in some fashion to the material conveyed on the informational card. Therefore, the owner of the informational card of the present invention obtains the lasting benefit and value of having an item of written information about a particular subject or experience, and the further ability to create independent functional item or items related to such subject or experience.
[0011] 3. Description of Related Art
[0012] It is known to provide functional items in packages or as assemblies, with such functional items being related to information provided in or on such packages or assemblies. For example, a pizzeria that delivers to a local area might distribute cards with their menu printed thereon, and such cards might also have a magnet adhesively attached thereto with the name and phone number of the pizzeria printed on the face of such magnet. In this example, the functional aspect of the information card is the menu, while the non-functional aspect is the magnet that would presumably be attached to a prospective customer's refrigerator for easy access to the information printed thereon. While the magnet is essentially non-functional with respect to the business except with respect to whatever advertising information it may embody, it is at least potentially functional for the customer, which is the reason the customer hopefully retains it in the modern throwaway society. Furthermore, the magnet serves as an immediate reference for dialing the pizzeria and possibly ordering items that don't require the perusal of the lengthier menu, while the menu serves as a more complete reference for perusing the totality of options.
[0013] Other methods of conveying information and functional articles in a single package are known in the greeting card art. For example, U.S. Pat. No. 2,547,359 to R. Bacharach discloses a combination greeting card and framed picture, with the picture shown through a cutout in the front of the card. The picture is removable and capable of being displayed in one's home, and thus provides the recipient with an essentially functional keepsake, while the card serves as a medium to convey a written message, i.e. non-functional information.
[0014] U.S. Pat. No. 4,070,778 issued to H. H. Mahler et al. discloses a combination greeting/post card with a wax-like adhesive applied to the back surface of the card for display-like attachment to a wall or the like. The front sheet of the card may be separated from the back and mailed as a postcard, leaving the back sheet adhered to the wall. The adhesive surface transforms the nonfunctional back part of the card into a functional display piece, while the greeting or message printed thereon is retained as a keepsake or mailed as a postcard.
[0015] U.S. Pat. No. 4,109,851 issued to D. T. Goates discloses a thermocontractive plastic plate adhesively applied to a postcard for subsequent thermal transformation into a novelty item. The card with the plate attached is placed in an oven and heated until the adhesive between the plate and the card dissolves and the plate shrinks into a novelty item. The Goates reference illustrates the application of a single, distinct, removable article from an information card, which article is transformed into a stand-alone novelty item.
[0016] U.S. Pat. No. 4,200,222 issued to E. P. Feuer discloses a removable decal with a removable backing sheet that is viewed through a window in the front sheet of a greeting card. The decal may be removed from the card and applied to another surface, thereby enabling the user to create a single, functional item from the removable decal. Similarly, U.S. Pat. No. 4,439,941 issued to E. Halperin discloses a greeting card with a removable and reusable insert in the form of a multicolored embroidered emblem that is adhesively or heat-applied to a separate article.
[0017] U.S. Pat. No. 5,284,365 issued to J. H. Stuart discloses a greeting card with a removable message insert of various embodiments. The removable insert is disclosed as being adhesively or magnetically attachable to a surface, or capable of being hung like a holiday ornament.
[0018] None of the prior art references of which the inventor is presently aware discloses an informational-type card assembly designed to convey information about a particular topic along with the provision of a plurality of functional keepsakes related to such topic and integrated into such product, with such plurality of functional articles capable of being applied to a separate object either independently of, or in conjunction with each other.
[0019] More specifically, none of the prior art references disclose an informational card having both a removable heat transfer and a removable emblem, patch or the like, each of which can be applied to separate articles independently of each other, or to the same article in an overlapping fashion, such that the combination of the applied articles on a single surface creates a homogeneous image consistent with, or distinct from an image shown on the informational card.
OBJECTS OF THE INVENTION
[0020] It is an object of the present invention, therefore, to provide an informational card having a plurality of separable elements or features that may each be removed from such card and applied to a separate article either independently of, or in conjunction with each other.
[0021] It is a further object of the present invention to provide an informational card having both utilitarian and non-functional aspects in a single assembly.
[0022] It is a still further object of the present invention to provide an informational card having a removable heat transfer and a removable emblem, patch or the like, each of which can be applied to separate articles independently of each other, or to the same article in an overlapping fashion.
[0023] It is a still further object of the present invention to provide an informational card having a removable heat transfer and a removable emblem, patch or the like, which when applied to the same article in an overlapping fashion create a homogeneous image.
[0024] It is a still further object of the present invention to provide an informational card having a removable heat transfer and a removable emblem, patch or the like, which when applied to the same article in an overlapping fashion create a homogeneous image consistent with, or distinct from an image shown on the informational card.
[0025] It is a still further object of the present invention to provide a folding informational card having a removable emblem positioned along an inside surface of the card that is viewable from the front surface of the card.
[0026] It is a still further object of the present invention to provide a folding informational card having a removable patch or emblem positioned along an inside surface of the card that is viewable from the front surface of the card and a removable heat transfer removably positioned along the back surface of the card.
[0027] It is a still further object of the present invention to provide an informational card having a removable heat transfer that is removably positioned along the back surface of the card.
[0028] It is a still further object of the present invention to provide an informational card having a removable heat transfer that is removably positioned along the back of the card and consists of the same image as viewed from the front of the card.
[0029] It is a still further object of the present invention to provide a folding informational card having a removable patch or emblem positioned along an inside surface of the card that is viewable from the front surface of the card and a removable heat transfer removably positioned along the back surface of the card that is also viewable from the front surface of the card.
[0030] It is a still further object of the present invention to provide an informational card having a removable heat transfer removably positioned along the back surface of the card and which is applied to a separate and distinct article via the direct application of heat through the information card.
[0031] It is a still further object of the present invention to provide an informational card having a removable emblem, patch or the like positioned along a front surface of the card, and a removable heat transfer positioned along the back surface of the card, that are both applied to a separate and distinct article together via the direct application of heat through the front surface of the card.
[0032] Still other objects and advantages of the invention will become clear upon review of the following detailed description in conjunction with the appended drawings.
SUMMARY OF THE INVENTION
[0033] An informational card incorporating a plurality of separable, functional articles that are removable from such card and capable of being applied to a separate article or articles, either independently of, or in conjunction with each other. More specifically, the informational card of the invention comprises a removable patch, embroidered emblem or the like, that may be adhesively or heat applied to a separate article, with indicia that bears some relation to the information conveyed on the card. A second removable article, preferably in the form of a heat transfer or the like, is also adhesively applied to the back of the information card, and such heat transfer or the like may be transferred to a separate article via the direct application of heat through the surface of the informational card. Means are provided in the second removable article to accommodate the placement or positioning of the first removable article during the conjunctive application of both removable articles to an article separate and distinct from the informational card.
[0034] The informational card of the present invention is designed to function as a keepsake, item of memorabilia, souvenir or the like, conveying information about a particular topic or item of interest. The informational card of the invention is also equipped with removable functional articles that enhance the value of the card by providing the owner with the ability to create additional keepsakes capable of being worn or otherwise displayed separate and apart from the informational card.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] [0035]FIG. 1 is a front view of the first surface or cover of the information card of the present invention.
[0036] [0036]FIG. 2 is a front view of the second and third surfaces, or inside surfaces, of the information card of the present invention.
[0037] [0037]FIG. 3 is a front view of the fourth or back surface of the information card of the present invention.
[0038] [0038]FIG. 3A is a front view of the fourth or back surface showing an alternative embodiment of the second removable article.
[0039] [0039]FIG. 4 is a front view of the inside of the card showing non-opaque third and fourth surfaces of the card of the present invention.
[0040] [0040]FIG. 4A is an alternative embodiment of the view of FIG. 4 with the addition of placement lines.
[0041] [0041]FIG. 5 is a front view of the inside surfaces of the card of the invention showing the second removable article on the second surface.
[0042] [0042]FIG. 6 is a front view showing application of the removable articles to a garment using the front cover of the card as a means of transferring such articles.
[0043] [0043]FIG. 7 is a front view of a garment with a first article applied thereto.
[0044] [0044]FIG. 7A is a front view of a garment with the first and second articles applied thereto to form a composite image.
[0045] [0045]FIGS. 8 through 10 are front views of an alternative, two-sided embodiment of the information card of the present invention.
[0046] [0046]FIG. 11 is a front view of the inside surfaces of an information card showing the second removable article positioned on a separate transfer sheet and inserted loosely between the second and third inside surfaces.
[0047] [0047]FIG. 12 is a front view of the inside surfaces of an information card showing the second removable article positioned on a separate transfer sheet that is removably attached between the second and third inside surfaces.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0048] The following detailed description is of the best mode or modes of the invention presently contemplated. Such description is not intended to be understood in a limiting sense, but to be an example of the invention presented solely for illustration thereof, and by reference to which in connection with the following description and the accompanying drawings one skilled in the art may be advised of the advantages and construction of the invention.
[0049] [0049]FIGS. 1 through 3 are front views of the surfaces of a folded information card of the present invention, with FIG. 1 illustrating the first surface 100 or front cover, FIG. 2 illustrating the second and third surfaces 200 and 300 respectively or the surfaces that are viewed once the card is opened, and FIG. 3 illustrating the fourth surface 400 or the back cover with the second surface 200 shown partially therebehind, with the first and second opposing surfaces 100 and 200 forming a first leaf of the card and the second and third opposing surfaces 300 and 400 forming a second leaf of the card. While the card of the present invention will be shown and described in some cases as a folded card, generally consisting of four separate surfaces, it will be understood that the elements or aspects of the present invention can preferably be applied to a card having at least two surfaces, and up to “x” number of surfaces as the case may be, as long as the card is able to accommodate the removable articles of the invention to be described herein. Furthermore, while the informational card of FIGS. 1 through 3 is shown with the fold or spine 250 , such fold or spine 250 occurring between the second and third surfaces 200 and 300 , aligned in a generally vertical orientation, it will be clearly understood that such fold or spine could also be aligned in a generally horizontal orientation as is commonly seen in the marketplace. In other words, the card of FIGS. 1 through 3 could also be rotated ninety degrees and be operative in the same manner as described herein.
[0050] [0050]FIG. 1 is a front view of the first surface 100 of the card of the invention with the card in a closed position. One viewing the front surface 100 of the information card of the invention would immediately notice certain desirable aspects of the card. First, there will usually be some identifying indicia 105 noted thereon representative of a particular experience or summarizing such experience. Such indicia 105 may, for example, be the name of a particular location, its logo or design or the like. Or such identifying indicia may be the title of a particular theme, as specifically shown in FIG. 1 with the title “PANSIES.” It will be appreciated that such indicia may also be textual or pictorial in nature. The first surface 100 also generally comprises an orifice or cutout 150 of a particular dimension, such that a first article 500 , shown here in the form of a bumble bee, removably attached to the third surface 300 (see FIG. 2) of the card will be visible through such orifice 150 . Surrounding such orifice or cutout 150 on the first surface 100 and around the first removable article 500 is a further design 125 , shown here as a grouping of pansies, which design or image 125 matches the design or image on the second article 600 (see FIG. 3, and FIG. 4 to be discussed), such second article 600 being removably attachable to the fourth surface 400 . Consequently, when both articles 500 and 600 are removed from the information card in a manner to be described herein, and applied to a separate object or article with the image of the first article 500 being surround by the image of the second article 600 , the combined image on such separate object will be identical to the image viewed by looking at the first surface 100 of the card of the invention when the card is in the closed position.
[0051] The first removable article 500 is either two dimensional, such as a sticker or a decal, or more preferably three dimensional, such as a patch of the embroidered variety or non-embroidered variety or some other type of three dimensional object. While stickers and decals are literally three dimensional, it will be understood for purposes of explanation that the distinction between a sticker and patch is an actual noticeable depth dimension that creates a unique impression for the viewer, and is also often associated with a unique feel to the touch. For purposes of illustration, the first article 500 , again shown for purposes of illustration as a bumble bee, will be described as an embroidered patch, or just a patch, which is clearly an article that can be considered as having a noticeable depth dimension or is, in general, “raised” from a particular surface. A patch is useful to illustrate some of the more desirable features of the invention because a patch, which has a depth dimension, creates a unique sensation when touched, and tends to look nicer when applied to articles of clothing or the like (as opposed to a mere sticker or decal). A three-dimensional patch, when applied to the third surface 300 of the card of the invention, will preferably show through the second surface 200 and be viewable along with the first surface 100 when the card is in the closed position. The patch 500 would be equipped with a combination heat seal and pressure sensitive back, allowing the patch to be heat applied to a textile article, such as to clothing for example, or pressed on via the pressure sensitive adhesive to virtually any other article or surface. While the patch 500 is preferably equipped with a combination heat seal and pressure sensitive back, it could also be equipped with either a pressure sensitive back only, or a heat seal only, or a combination surface preferably.
[0052] As shown in FIGS. 1 and 2, the cutout 150 extends between the first and second surfaces 100 and 200 respectively, and the outline dimension of the cutout 150 is designed to accommodate the dimension of the first article 500 , such that, as noted above, the article 500 might preferably extend through the cutout 150 and form part of the front surface view when the card is in the closed position and viewed in this manner. Of course, the cutout 150 could be dimensioned so that the article 500 does not extend through such cutout, but is instead merely exposed through such cutout, in which case its image will enhance the overall view of the front surface 100 as opposed to both its image and its depth, if any. If the first article 500 was a patch, then such patch would be exposed through the cutout 150 when the card is in the closed position, creating the impression that the patch 500 forms part of the first surface 100 , even though it would temporarily reside on the third surface 300 as shown in the embodiment of the invention in FIGS. 1 through 3.
[0053] The second article 600 (see FIG. 3) removably attachable to the fourth surface 400 is also either two dimensional, such as a sticker or a decal, or three dimensional, such as a patch of the embroidered variety or non-embroidered variety or some other type of three dimensional object. For purposes of illustration, the second article 600 will be preferably in the form of an image-bearing heat transfer of the t-shirt variety, i.e. for transfer to t-shirts or the like, which does not have as extensive a depth dimension as a patch, but does have more of a depth dimension than a sticker or a decal. The second article 600 in the form of a heat transfer or the like would be equipped both with an adhesive or temporary adhesive first surface mountable to the fourth surface 400 of the card, and preferably a combination heat seal and pressure sensitive surface on the other side, or second side, of the transfer, allowing the transfer to be temporarily pressed onto a textile article and positioned thereon prior to the more permanent heat application of the transfer to such article of clothing or the like. Such application of the second article 600 to an article of clothing or the like would preferably occur by the direct application of heat, by an iron or other heat press or the like, applied to the third surface 300 of the card, which heat would transfer through such third surface 300 to the fourth surface 400 , thereby dissolving the temporary adhesive securing first side of the second article 600 to the fourth surface 400 and perfecting the heat application of the second article 600 to an article of clothing or the like.
[0054] It will be understood that the first side of the article 600 will be the finished side, which will be ultimately viewable on the clothing or the like, and the second side may be unfinished. However, the second side may also be finished or decorated to form a more complete back to the card of the invention. Furthermore, in a more modern type of transfer, the transfer attached to the rear of the card or the fourth surface 400 will have merely a color transferable second surface that will, upon the application of heat, be transferred directly to the article of clothing, leaving the transfer itself still attached to the back of the card. In such case, the separate transfer will be attached to the back of the card or surface 600 by permanent adhesive. In a still further type of arrangement, the back of the card will itself be the transfer, the image and color of which may be transferred directly to the clothing surface by the application of heat from an iron or the like.
[0055] As shown in FIG. 3, the second article 600 preferably has a cutout 155 , similar to the cutout 150 present between the first and second surfaces 100 and 200 , and bears an image that is preferably, although not necessarily, identical to the design or image 125 present on the first surface 100 of the card. If desired, the second article 600 might not have a cutout 155 but might instead have a continuation of the design or image 125 so that the second article, when applied to a separate object alone, i.e. without the conjunctive application of the first article 500 , does not appear discontinuous or with a cutout in the central portion of the article 600 . Since the second article 600 is preferably in the nature of a heat transfer or the like, the image or design on such second article 600 is usually not viewable by viewing the fourth surface 400 , since the design side of the second article would be initially, temporarily adhesively attached to the fourth surface 400 as shown. Since the second article 600 may, however, as explained above, be merely a heat transferrable pigment image on the back of the card or fourth surface 400 , the second article may be viewable on the back of the card as a mirror image of what will be transferred ultimately to a clothing article or the like (see FIG. 3A).
[0056] The operation of the preferred embodiment of the card of the present invention is as follows. A recipient of the card would view the first surface 100 and notice a composite image or design comprised of the design or image 125 surrounding a first removable article 500 , such first removable article 500 appearing or peeking through a cutout 150 in the first surface 500 . Other indicia 105 on the first surface 100 would summarize or introduce the subject matter of the card to the recipient. By viewing the first surface 100 or cover of the card, the recipient is able to touch or feel the surface texture of the first article 500 . Another highly desirable feature of the cover image is that the cover of the card illustrates the composite design of the two articles, namely articles 500 and 600 , as such composite design might appear on a separate article, such as a shirt for example. Since the design or image of the second article 600 is preferably identical to the design or image 125 on the first surface 100 , and since the second article 600 comprises a cutout 155 that is preferably identical to the cutout 150 in the first surface 100 and/or is preferably identical to the outline dimension of the first article 500 , the recipient is able to initially view the composite image or design of both articles 500 and 600 as if such articles were removed from the card of the invention and applied to a separate article, such as a shirt, by the recipient. In other words, the recipient is able to view the card and realize the nature of the design that can be extracted from the articles attached to the card and applied to a separate article such as a shirt or the like. The recipient or purchaser of a card is therefore able to select a particular design or image that he or she would wish to apply to a separate article, such as a shirt, by merely perusing the front covers of the available cards.
[0057] After the purchaser or recipient opens the card of the invention, he or she will immediately notice the first article 500 temporarily and preferably attached to the third surface 300 of the card. The second and third surfaces 200 and 300 will preferably be enhanced with further indicia, i.e. text, graphics or a combination of the two, or information about the particular experience illustrated by such card or about the topic of the card, and may even include written or pictorial (or both) instructions on how a recipient or user may fully utilize the removable articles attached to such card. Since such first article 500 is preferably equipped with a combination heat seal and pressure sensitive back, the article 500 may be removed from the surface 300 and pressed onto a separate object (see FIG. 7), or it may be temporarily applied to a garment via the pressure sensitive back and then heat applied in a more permanent fashion to such garment for a lasting effect (again, see FIG. 7). The design or image of the first article 500 is preferably, although not necessarily, printed on the surface of the card underneath the removably attached first article 500 , such that the design or image of the first article 500 is retained as part of the card once the actual first article 500 is removed from the card. The cutout 150 may also preferably, but by no means necessarily, be provided with a non-opaque covering that may also extend slightly forward to protect the article 500 while the card is displayed on a rack in a vending establishment. This would be particularly useful if the card of the invention was not vended it is own wrapping or other package-type container.
[0058] Instructions will also preferably be provided on one of the surfaces of the card or in an insert-type sheet vended or otherwise provided with the card concerning the application of the second article 600 to a garment or the like. The second article 600 , as described above, is preferably a heat transfer, which is generally heat applied to a garment though the forceful application of heat via an iron or other type of heat press. The card of the invention provides the owner of the card with the necessary means to transmit the application of heat through the article 600 and onto a garment or the like. The surfaces of the card are impervious to the direct application of heat from an iron or the like, such that the second article 600 may be heat applied to a garment through the application of heat to the surface of the card directly upon the surface on which the article 600 is temporarily adhesively applied. In other words, one must merely position the card such that the second article 600 , currently adhesively secured to the fourth surface 400 , is in the proper location against a garment, and then apply heat directly to the third surface 300 (see FIGS. 2 and 3), which heat will be transmitted though the third and fourth surfaces 300 and 400 and to the second article 600 , which heat releases the article 600 from its temporary adhesive bond with the fourth surface 600 and activates the heat seal that creates a more permanent-type affixation to a garment or the like. Alternatively, as explained above and shown in FIG. 3A, merely the pigment from the transfer, which in this case may be the fourth surface or sheet itself, may be released by the heat and applied to an adjacent surface.
[0059] It should be noted that another desirable feature of the card of the present invention, and more particularly the nature of the removable articles attached to the card, is the manner in which such articles may be removed and applied to a separate object either independently of, or in conjunction with each other on such separate object. Since the cutout 155 in the second article 600 is specifically designed to accommodate the dimensions of the first article 500 , it will be understood that a highly desirable feature of the card of the invention will be the conjunctive heat application of both articles 500 and 600 to a separate object, with such first article 500 fitting nicely within the cutout 155 of the second article 600 , such that a composite image may be created on such separate object that matches the image viewed on the cover of the card (see FIG. 1). In other words, the first article 500 can be removed from the surface of the card of the invention and adhesively applied to a garment or the like, and then the second article 600 can be positioned over the first article 600 such that the first article 500 is positioned within the orifice or cutout 155 of the second article, after which both articles can be simultaneously heat applied to a garment or the like, resulting in a composite image on such garment that is consistent with the image shown on the cover of the card when the card is in the closed position. Normally, if the first article 500 is an embroidered patch, such article 500 must be separated or protected by a separate sheet or covering from the direct application of heat from an iron or the like. However, the use of the card surface 300 (in FIGS. 2 and 3) to simultaneously and directly apply heat to the first and second articles, now located adjacent the fourth surface 400 , protects both articles from the hot surface of the iron or the like, and makes an additional sheet separate from the card itself unnecessary. Consequently, the information card of the invention acts as a protective surface during the heat application of the articles 500 and 600 to a separate garment surface or the like.
[0060] It should be noted that the card surfaces are constructed in such a manner that the removal of the articles 500 and 600 through manual means, heat means or otherwise, does not destroy the integrity of the card surfaces or the indicia noted thereon, thus allowing the informational card of the invention to be used as a keepsake, souvenir or collectible, both with and without the removably attached articles attached thereto.
[0061] The positioning of the information card of the invention against an article of manufacture, such as a garment or the like, in preparation for heat application of the second article 600 is fairly straightforward. The second article 600 will preferably be centered on the fourth surface 400 of the information card, and therefore, the card itself will serve as a positioning and guiding means against a garment or the like. FIG. 4 is a front view of an alternative embodiment of the information card of the invention, shown with non-opaque mounting surfaces 300 and 400 for easier positioning of the second article 600 against a garment or the like. Non-opaque can either mean transparent, semi-transparent, translucent or the like. A purchaser of the card of FIG. 4 might find it useful or desirable, for example, to be able to see the placement of the second article 600 , through the third and fourth surfaces 300 and 400 , and against a garment or the like. Non-opaque surfaces 300 and 400 would also be desirable if, for example, the first article 500 was removed and positioned on a garment, and it became necessary to view or visualize the subsequent placement of the second article 600 about or around the first article (via the cutout 155 ) prior to heat application of both articles to a garment or the like. It might also be desirable to have non-opaque card surfaces if the garment or the like has additional indicia that should be avoided or circumvented during the application of the image-bearing articles to such garment, i.e. necessitating precision placement of such articles to such garment. It might also be desirable to have placement lines 315 , as shown in FIG. 4A, for the positioning of the card against a garment surface or the like, although placement lines along a non-opaque surface might not be too desirable at times, particularly because the second article 600 would be viewable through the heat application surface prior to heat application of the articles 500 and 600 to the garment.
[0062] [0062]FIG. 5 is a front view of surfaces 200 and 300 of an alternative embodiment of the information card of the present invention, showing the first article 500 removably attachable to the third surface 500 and the second article 600 removably attachable to the second surface 600 (as opposed to the fourth surface 400 as discussed above). The first surface 100 of the card of FIG. 5 would be unchanged as compared with the embodiments discussed above. Having the second article 600 attached to the second surface 200 as opposed to the fourth surface 400 has one distinct advantage over the embodiments of the invention described in connection with FIGS. 1 through 3, particularly during the heat application of both articles to a garment or the like. Once the first article 500 is removed from the third surface 300 and applied to a garment or the like, the second surface 200 must merely be placed directly over the first article in preparation for heat application to the first surface 100 and through the second surface 200 , such that the first article 500 extends through the orifice or cutout 155 in the second article 600 and cutout 150 between the first and second surfaces 100 and 200 . Having the first article 500 prepositioned on the garment and extending through the first and second surfaces of the card almost assures that the first article will be heat applied to the garment in proper position with respect to the second article, i.e. with the first article positioned within the cutout 155 of the second article.
[0063] One of the disadvantages of having the second article 600 temporarily affixed to the second surface 200 , as opposed to the fourth surface 400 , is the space taken by the second article 600 , which otherwise might have contained written or pictorial descriptions or the like about the subject matter of the card. In other words, if the second article 600 were affixed to the back cover, or fourth surface 400 of the card, there would be more room to include informational material on the inside of the card, or on the second and third surfaces 200 and 300 . If the second article 600 were positioned on the inside of the card, it would be possible, although probably not desirable, to have some additional information noted on the back or the fourth surface 400 of the card. However, if the creator of the information card does not require a lot of room, or does not require that there be information noted on the second and third surfaces 200 and 300 , but instead only on the third surface 300 , then it really doesn't matter that the second article 600 is taking up room on the second surface 200 , which might otherwise just be blank.
[0064] Another possible disadvantage of having the second article 600 on the second surface 200 with the heat being applied against the first surface 100 and directly against the first article 500 already prepositioned on a garment and peeking through the cutouts 150 and 155 , is that the direct topical application of heat against the first article 500 might harm in some manner the outer surface of the first article 500 , particularly if such first article is an embroidered patch. Usually, an additional sheet of material is placed between a patch and a direct application of heat from an iron or like, in order to protect the patch from the hot metal or other surface as the case may be. With the embodiment of FIG. 5, it would preferably be necessary to place an additional sheet of material over the first surface 100 prior to the application of heat against such surface in order to protect the first article 500 , which would be exposed through the cutouts 150 and 155 . One way to overcome this problem, without the need to find or otherwise obtain and use an additional protective sheet, would be to provide a temporary flap of protective material 510 (see FIG. 6) removably attachable to the first surface 100 and covering the entire cutout 150 , which flap of material would protect the exposed surface of the first article 500 during the heat application, and which flap of material 510 may then be easily removed from the first surface 100 after the articles have been transferred to the garment 900 or the like. Another way to overcome this problem would be to provide a temporary covering 520 (see FIG. 7) removably attachable to the outer surface of the first article 500 , which would protect the first article 500 during the direct heat application to a garment or the like, and would be easily removable by peeling or the like once the first article 500 was heat transferred to the garment. A further method of providing heat protection to the first article 500 would be to use a non-opaque dust cover, as described above, that is sufficiently thick or heat absorbent to also act as a heat shield over the article 500 . Of course, if the first article 500 is merely going to be adhesively applied to a separate object, such as a dry flat surface, then it might not be necessary to retain the protective covering 510 or 520 (see FIGS. 6 and 7) for any meaningful period of time, and it can be discarded if the owner of the card does not intend to heat apply such first article 500 .
[0065] [0065]FIG. 8 is a front view of an alternative, two-sided or two-surfaced embodiment of the information card of the present invention, having a first or front surface 700 , a second or back surface 800 , and indicia or informational material 725 provided on such front surface 700 . The second removably attachable article 600 is shown in phantom attached to the second surface 800 in the same manner as previously described above, with a cutout 155 within such second article 600 designed to accommodate the placement of the first removable article 500 during simultaneous heat application of the two articles to a garment or the like. In the two-sided embodiment of the invention of FIG. 8, the first article 500 would be removably attachable to the first surface 700 , similar to the manner in which the first article 500 is removably attachable to the third surface 300 of FIGS. 2 and 4. In fact, the two-sided embodiment of FIG. 8 is essentially the same as the four-sided embodiment of FIGS. 1 through 3, for example, but without the first and second surfaces 100 and 200 of FIGS. 1 through 3. However, the first article 500 of FIG. 8 is actually attachable directly to the front cover 700 , as opposed to being viewable through a cutout 150 as in FIG. 1.
[0066] Since the first article 500 of FIG. 8 is attachable directly to the surface 700 , it may be removed directly from such surface 700 and either pressure applied to a separate object, such as a garment, or temporarily pressure applied to a garment in preparation for the heat application of just the first article 500 , or the combination of the first and second articles 500 and 600 through the direct application of heat through the front surface 700 . As with all of the embodiments discussed herein, the surfaces of the information card may be opaque or non-opaque depending on the desired effect and the desires of the purchasers of such card. If the front surface 700 was completely opaque, then the positioning of the card of FIG. 8 over a prepositioned, pressure applied first article 500 , for the heat application of both articles to a garment, would be somewhat difficult. However, if the front surface 700 was non-opaque, or if just the surface 750 directly underneath the first article 500 (see FIG. 9 illustrating the first surface without the first article attached thereto) were non-opaque, the subsequent placement of the card over the prepositioned first article 500 , in order to line up the cutout 155 of the second article 600 with the outline or dimension of the prepositioned first article 500 , would be much easier, since the first article 500 would be viewable through such non-opaque section 750 of the front surface 700 . With the embodiments of FIGS. 8 and 9, the direct application of heat to the first surface 700 , with the first and second articles 500 and 600 prepositioned adjacent a garment or the like, is transmitted through the first and second surfaces 700 and 800 for the heat application of the articles 500 and 600 to such garment, and the first surface 700 also protects against the heat problems that might occur with the direct application of heat to the first article 500 (see. FIGS. 6 and 7 and the discussion related thereto).
[0067] [0067]FIG. 10 is a front view of yet another alternative embodiment of the present invention, and more particularly an alternative embodiment of the invention described in FIGS. 8 and 9, showing a two-sided card having a removably attachable protectible layer 520 on the outer surface of the first article 500 , allowing for the direct application of heat to the first article 500 , and a heat dissolvable undersurface 750 directly under the first article 500 and extending between the first and second surfaces 700 and 800 . The heat dissolvable undersurface 750 allows the application of both articles 500 and 600 to a garment or the like without having to first remove and separately preposition the first article 500 on the garment. One would merely position the card of the invention on a textile surface, such as a shirt or other garment, and apply heat directly to the first surface 700 and the protective covering 520 of the first article 500 , which heat would dissolve the undersurface 750 and allow for the subsequent heat application of the first article 500 directly to the garment.
[0068] Consequently, one could take the card of the invention adorned with informational material and removable articles, and apply such card directly to a garment, and the application of heat to such card would result in a garment adorned with the articles that were originally attached to the card, and a card containing information about a particular subject or experience (no longer having removable articles attached thereto). In other words, if one purchased the informational card of the invention, one would actually be purchasing the ability to create a separate keepsake in the form of a garment or other physical object adorned with heat applied articles, with the informational card serving as the method or means for applying such articles to such a garment. Once the articles are removed from the informational card, if desired, the informational card itself serves as a meaningful keepsake or memento, since it would generally be adorned with interesting information about a particular place, thing or event, with the removable articles being related in some fashion to such information on the card.
[0069] The second removable article 600 , generally in the form of a heat transfer or the like, is primarily designed for heat application in conjunction with the first removable article 500 , generally a patch or the like. The informational card of the present invention could, for example, be vended with the second article loosely removable from the card assembly either as an insert sheet 920 to the card assembly (see FIG. 11), or loosely attached via breakable means 950 or the like (see FIG. 12). In FIG. 12 for example, the second article could be attached to a sheet that is connected to the card assembly via breakable means 950 , i.e. a tear line, fold line, perforated line or the like. In any case, the second article 600 should be able to accommodate the positioning of the first article 500 within an orifice or cutout of the second article, and it will understood that while only two removable articles are discussed herein, the information card of the present invention can comprise more than two removable articles, which then, when applied to a garment, or other surface or the like, would create an image that is consistent with the image shown on the informational card.
[0070] The present inventor contemplates many uses for the informational card of the present invention. For example, auto dealerships wishing to advertise or solicit business might distribute information cards having information about the dealership printed thereon, accompanied by removable articles related to the dealership logo or the automobiles vended by such dealership. Zoos might distribute or sell informational cards for conveying information about the zoo or a particular animal at the zoo, with removable articles associated with such card and related to the zoo or a particular animal at the zoo. In fact, a zoo could vend many different informational cards having the same information printed thereon, but different removable articles associated therewith, directed to purchasers, for example, that might wish to create a garment each with a different type of animal. School, colleges and universities might sell informational cards with interesting information about the college, as well as removable articles associated therewith, which gives the purchaser the ability to create a personalized garment having school-bearing indicia applied thereto, while retaining the informational card for future reference about that particular school or institution of learning. Other typical uses would include, but would be by no means limited to, tourist attractions and theme parks, concerts and plays, or even manufacturers wishing to distribute information and articles about a new or emerging product.
[0071] The informational card of the present invention, therefore, provides a useful tool for disseminating information about a particular person, place, thing or experience, while at the same time enabling recipients of the card to create additional keepsakes or mementos from removable articles attached to the card. The removable articles enhance the overall image of the card, and are designed to interact with each other during the final positioning and attachment to a garment or the like. The card of the invention also allows a recipient to review the final image or design created from the application of such removable articles to a garment or the like, and therefore, provides a means to discriminate between different informational cards. The card itself also provides a tool or the medium for application of the removable articles to a separate object, requiring only that the recipient have an iron or the like, with the card providing all of the other means for fully utilizing and applying the articles to a separate object such as a garment.
[0072] While the present invention has been described at some length and with some particularity with respect to the several described embodiments, it is not intended that it should be limited to any such particulars or embodiments or any particular embodiment, but it is to be construed with references to the appended claims so as to provide the broadest possible interpretation of such claims in view of the prior art and, therefore, to effectively encompass the intended scope of the invention. | An informational card is disclosed incorporating a plurality of separable, functional articles that are removable from such card and capable of being applied to a separate article or articles, either independently of, or in conjunction with each other. The removable articles, such as a patch, embroidered emblem, heat transfer or the like, may be removed from the card and adhesively or heat applied to a separate article, with indicia that bears some relation to the information conveyed on the card. One of the removable articles has a cutout to accommodate the placement of a first removable article during the conjunctive application of a series of removable articles to an article separate and distinct from the informational card. The informational card of the present invention functions as a keepsake about a particular topic, and is equipped with removable articles that enhance the value of the card by providing the owner with the ability to create additional keepsakes capable of being worn or otherwise displayed separate and apart from the informational card. | 54,859 |
This application claims priority under 35 USC § 119 (e) (1) of provisional application Ser. No. 60,064,309, filed Nov. 5, 1997.
FIELD OF THE INVENTION
The present invention is generally related to wireless communications systems, and more particularly to fixed wireless systems provided with HomeZone service whereby subscribers are provided communications service, and billed accordingly, depending on whether or not a subscriber's mobile station (MS) is located within one of its designated HomeZones.
BACKGROUND OF THE INVENTION
The implementation of wireless communications systems throughout the world is growing rapidly. This can be seen by the extensive sales and marketing of mobile cellular phone service throughout North America as well as the rest of the World. Existing and emerging technologies include AMPS, TDMA, CDMA, and GSM just to name a few. In these systems, a subscriber of an MS is typically billed for calls at a rate determined by a plan contracted to by the subscriber of the MS, whereby the rate per minute may be based on the time of day, the amount of use and the geographical location of the MS during a call.
Another emerging wireless communication system is known as a fixed wireless system. In many parts of the world including Europe and Asia, subscribers are being provided with wireless communication transceivers e.g. mobile stations as their primary communication device for use within a residence, business and other defined locations. These fixed wireless transceivers are specially suitable where wireline services are to date not available, inadequate, or exceptionally expensive to install. With the decreasing cost of wireless transceivers and supporting infrastructure, those places of the world in need of new or upgraded communication systems are finding fixed wireless systems as economically attractive and versatile solutions.
In fixed wireless communication systems, a subscriber's mobile station is assigned to one or more HomeZones. Each HomeZone defines a geographical home area in which the wireless mobile station is to receive and originate wireless calls at a predetermined low billing rate. While it is primarily intended that a subscriber will primarily use its mobile station within the HomeZone areas, these mobile stations may be transported by a subscriber outside the HomeZone calling areas and may be allowed to originate or receive calls outside the HomeZone area at another predetermined billing rate.
The HomeZone service allows telecommunications providers to define the HomeZone calling areas for their MSs, where the tariff for calls originated and terminated in one of the HomeZones is different than the regular wireless tariff. The HomeZone service is attractive for telecommunications providers wanting to offer both fixed wireless and wireless services to subscribers over one mobile phone. One of the significant costs in providing wireline services is laying copper to each subscribers home. HomeZone service eliminates this cost by using wireless systems which don't require the cost of laying copper. The HomeZone service allows the provider to charge subscribers a particular tariff when they use their mobile station in one of their HomeZones at their wireline rate, and at another tariff when they use their mobile station outside their HomeZones at their wireless rate. The wireline rate is usually less expensive than the wireless rate. This attractive to consumers because they are charged the same low rates in their Homezone as they would have been charged by a wireline provider but without the hassle of multiple phones bills.
As part of the HomeZone feature, on call termination, the location of the mobile station must be determined before the call is routed to the network access element, such as a visitors mobile switching center (VMSC), currently serving the mobile station, so that the network can potentially disallow or reroute the termination if the subscriber's mobile station is not in one of is HomeZones. There is a need to provide a method for determining whether a mobile station is located in one of its HomeZones, and also a method for speeding up the potential termination to the mobile station that may follow.
SUMMARY OF THE INVENTION
The present invention achieves technical advantages as a method of establishing call termination to a called mobile station in a wireless communication network which can be only allowed to receive call terminations in one of its HomeZones by determining the mobile station's location and identity before completing a call termination to the network access element currently serving the mobile station.
In the preferred embodiment of the present invention, the method comprises first determining if a call termination received by a wireless communication network is a HomeZone type call. This may be done, for instance, at a gateway MSC by identifying prefix digits attached to the call. Upon determining that the call termination is a HomeZone type call, the location of the called mobile station to the cell level is first identified in the wireless communication network before routing the call termination to a network access element currently serving the mobile station. It is then determined if the identified location (e.g. serving cell of the mobile station) is within one of the mobile station's HomeZones. If the mobile station's location is determined to be within one of the mobile station's HomeZones, then the call termination is routed to the network access element currently serving the mobile station, and the call termination is completed to the mobile station by the network access element currently serving the mobile station. Preferably, the network access element comprises an MSC, but could comprise other equivalent network devices. If the mobile station is determined to be outside its HomeZones, the call may be routed by the network to the mobile stations voicemail, or to an associated wireless phone number and billed accordingly.
According to the present invention, a mobile station radio link is established between the MSC currently serving the mobile station and the mobile station during the mobile station location process, wherein the call termination is completed to the mobile station on the same mobile station radio link. The radio link is preferably established by sending a PSI message from a HLR to the MSC currently serving the mobile station and paging the mobile station, whereby the mobile station then responds to the page with a page response to the serving MSC. If the mobile station is currently on a call, the location of the MS is known to the serving MSC and is returned to the HLR. If a subsequent termination arrives at the serving MSC, then the call termination to the mobile station is completed if the MS is configured to receive multiple calls e.g. call waiting, without establishing a new radio link between the MSC serving the mobile station and the mobile station.
A PAGE_RESPONSE message which includes the mobile station's identity is generated in response to the page message by the mobile station. The identity included in the PAGE_RESPONSE message comprises preferably either the mobile station's International Mobile Subscriber Identity (IMSI) or Temporary Mobile Subscriber Identity (TMSI). If the response contains the TMSI, the TMSI is used by the serving MSC to find the IMSI. The page response also includes the mobile station's current Cell ID and the mobile station's current location area code (LAC). The mobile station's identity, LAC, and Cell ID are all sent by the MSC serving the mobile station to the home location register (HLR) of the mobile station. The mobile station's identity, LAC and Cell ID are then sent to a service control point (SCP) of the wireless communication network. The SCP determines if the mobile station is in one of the mobile station's HomeZones. If the SCP determines the mobile station is in one of its HomeZones, the SCP notifies the gateway MSC of the wireless communication network to complete the call termination to the mobile station. If the mobile station is determined to be outside its HomeZones, the call may be routed by the SCP to the mobile station's voicemail, or to an associated wireless phone number and billed accordingly.
The present invention achieves technical advantages by determining the location of the mobile station to the cell level before the call is routed to the serving MSC, and speeding up the potential call termination to the mobile station that may follow.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to FIG. 1, there is illustrated a typical fixed wireless communication network generally which is well suited to benefit from the method of the present invention; and
FIG. 2 is flow diagram of a method of identifying a mobile station location to provide HomeZone service according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, there is generally shown at 10 a typical fixed wireless communication network which is adapted to provide HomeZone service according to the method of the present invention. The network 10 is seen to comprise a fixed network 12 which may comprise a public switched telephone network (PSTN), a gateway mobile switching center (GMSC) 14 and a subscriber switching center 16 which may be a MSC, serving a wireless mobile station (MS) 18 via a base switching station (BSS) 20 . MS 18 is seen to be assigned to one or more HomeZone location areas, one HomeZone area generally shown at 22 , which may be one geographic cell area served by BSS 20 . Associated with the serving/visited switching center MSC 16 is a visitors location register (VLR) 26 . A home location register (HLR) 30 is assigned to handle all of the MS 18 information, including the address of the MSC currently serving the MS, service capabilities, etc. A service control point (SCP) 32 interfaces with the GMSC 14 and HLR 30 .
The present invention provides a method to determine if the MS 18 subscribing to a HomeZone service is in one of its HomeZones 22 before routing a call termination to the network access element 16 serving the MS, such as MSC 16 . One HomeZone 22 may be a subscriber's office, another HomeZone 22 may be a subscriber's home and so forth. The present invention allows the network 10 to potentially disallow the termination of a call to the MS 18 if the MS is not in one of its HomeZones 22 . The present invention also provides a method to precisely determine the MS's location. In addition, the present invention speeds up the potential termination to the MS that may follow by using the same radio link in the call termination that was used to find the mobile stations location.
By way of illustration, but without limitation to the specific implementation that will soon be described, reference is made to the network of FIG. 1 and the message flow of FIG. 2 which illustrates the preferred embodiment of the present invention to provide the HomeZone feature. The present invention is illustrated and described in considerable detail to provide an understanding of implementation and use of the present invention. It is to be understood that some of the basic elements of the network 10 can be substituted with other equivalent network elements to provide the intended function. For instance, the gateway MSC (GMSC) 14 can be substituted with other network access elements e.g. routers, depending on the technology implementing the HomeZone feature. The present invention is ideal for implementation in a GSM network, but can function in other types of networks as well.
With reference to FIG. 1, upon a call termination from the fixed network 12 to GMSC 14 , the GMSC 14 determines if the called number is a HomeZone type number. This is preferably done by ascertaining call data e.g. prefix digits provided with a call termination from the fixed network 12 , although other methods are possible. The GMSC 14 then queries the SCP 32 to determine if the termination is allowed to the intended MS 18 . To determine this, the SCP 32 then queries the HLR 30 to find the location of the MS 18 , and specifically, to determine if the MS 18 is located in one of its assigned HomeZones 22 . The HLR 30 then queries the MSC 16 known by the HLR 30 to be currently servicing the MS 18 , whereby the serving MSC 16 will page the MS 18 . The MS 18 responds to the page with a PAGE_RESPONSE message including its exact location including its current location area code (LAC) and current Cell ID, which is known by the mobile station based on broadcast messages by the serving cell. It is noted that the serving MSC 16 will know the LAC that the MS is located in, before paging, but the LAC is not enough information for the SCP to determine if the MS is in one of its HomeZones 22 . The PAGE_RESPONSE message also includes the mobile station identify, comprising the mobile station International Mobile Subscriber identify (IMSI) or Temporary Mobile Subscriber Identify (TMSI). If the response includes the TMSI, the TMSI is used by the serving MSC to determine the IMSI.
The MS 18 will provide a page response containing its LAC and Cell ID to the serving MSC 16 , which information is then sent to the HLR 30 by the serving MSC 16 for that MS 18 . The HLR 30 then sends the LAC and Cell ID to the SCP 32 , which then instructs the GMSC 14 if and how to route the call to the MS 18 . For example, if the SCP 32 determines the MS 18 is in one of its HomeZones 22 , the call will be terminated to the MS 18 . If, however, the MS 18 is determined to be outside its HomeZones 22 , the call may be forwarded to the voicemail associated with MS 18 , or, terminated to an associated wireless phone number, e.g. MSISDN number, associated with the MS 18 wherein the subscriber is billed at the wireless rate, which is usually higher than the wireline rate.
After sending the MS LAC and Cell ID location information back to the SCP 32 via the HLR 30 , it is specifically noted that the serving MSC 16 leaves the radio link (RR) connection up in anticipation of a reception of a call termination for that MS 18 . A timer at serving MSC 16 having a predetermined stop time e.g. 3 seconds is started at the serving MSC 16 once the MS LAC and Cell ID information has been sent to the HLR upon receiving the PAGE_RESPONSE message from the mobile station 18 . If a call termination does not arrive to the serving MSC 16 within the specified time, the established RR connection is then cleared by the serving MSC 16 . However, if the call termination does arrive within the predetermined time, the RR connection established between MSC 16 and MS 18 when the location of the MS was determined is then used. Thus, the MS 18 does not need to be paged again. The present invention achieves technical advantages by providing a significant improvement in time and processing over the prior art. The call set up time is improved by not having to page the MS again, by re-using the RR connection that was set up when the location of the MS was first determined.
To more fully understand the preferred embodiment for providing the present invention, reference is now made to the preferred message flow diagram in FIG. 2 . The steps illustrated in FIG. 2 correspond to the message number illustrated in FIG. 1 . Again, this specific implementation is preferred, although variations are possible and covered by the present invention.
At step 1 , the GMSC 14 is seen to receive an incoming call termination seen as an Initial Address Message (IAM) from the PSTN 12 . The GMSC 14 then determines if this call termination is to be a HomeZone termination. This is determined by ascertaining a call data e.g. prefix digits provided at the beginning of the call termination which identifies the type of call. At step 2 , the GMSC 14 initiates a query message to the SCP 32 by sending an InitDP message. At step 3 , the SCP 32 initiates identifying the location of the mobile station 18 by sending an AnyTimeIntegration message (ATI) to the HLR 30 .
At step 4 the HLR 30 requests the called MS's location from the VLR 26 associated with the serving MSC 16 using the Provide MS Information (PSI) message.
At step 5 , if the mobile station 18 is not on a call, the visited MSC 16 serving the mobile station 18 pages the mobile station 18 to ascertain its location. At step 6 , the mobile station 18 responds to this page with a PAGE_RESPONSE message to the serving MSC 16 containing its Location Area Code (LAC) and its Cell ID. In this regard, the present invention uses the PSI message in a novel way to trigger the serving MSC 16 to ascertain the MS 18 location. The MSC 16 starts the 3 second timer upon receipt of the PAGE_RESPONSE message, and leaves the established radio link to the MS 18 up in anticipation of an imminent call termination.
At step 7 , the VLR 26 sends this LAC and Cell ID to the HLR 30 in a PSI response message. In step 8 , the HLR 30 forwards the LAC and Cell ID information to the SCP 32 using an ATI Response message.
At step 9 , based on the specific location information received, the SCP 32 determines if the mobile station 18 is in one of its Home Zone's 22 , or if it is outside the HomeZones 22 .
At step 10 , if the SCP 32 determines in step 9 that the mobile station 18 is in one of its HomeZones 22 , the GMSC 14 sends a Send Routing Info (SRI) message to the HLR 30 . If the SCP 32 , however, determines the MS 18 is out of its HomeZones, the call is either terminated to the voicemail of the MS 18 at the wireline rate, or terminated to the MS 18 but at the wireless rate. The servicing MSC 16 handles billing of the call.
At step 11 , the HLR 30 responds to the GMSC 14 with a subscriber MS Roaming Number (MSRN) for the terminating mobile station 18 in the SRI ACK message. The MSRN number is generated by the serving MSC 16 and is included in the PRN ACK message per the GSM standard. At step 12 , the GMSC 14 then sends an IAM message to the visited MSC 16 .
At step 13 , the visited MSC 16 terminates the call as normal, except that the Paging is skipped since it has already been done earlier in step 5 , as long as the timer at MSC 16 has not expired. The existing radio link established with MS 18 in step 5 is used. As a result, the Authentication Request message is the first message sent, if authentication is required, to the mobile station 18 after the IAM message is received from the GMSC 14 .
The forgoing message flow as described with reference to FIG. 2 in view of FIG. 1 is the preferred implementation of the present invention, however, limitation to these specific messages is not to be inferred by the present invention. The present invention encompasses identifying if a MS is in one of its HomeZones prior to routing a call termination to the serving switching center for the mobile station, and using an existing RR connection to eliminate paging a mobile station a second time if a call termination is to be established. A timer is utilized at the switching center serving the MS, upon which the expiration of the timer of the RR connection is released.
Though the invention has been described with respect to a specific preferred embodiment, many variations and modifications will become apparent to those skilled in the art upon reading the present application. It is therefore the intention that the appended claims be interpreted as broadly as possible in view of the prior art to include all such variations and modifications. | A method of establishing call termination to a mobile station of a called subscriber in a fixed wireless communication network which can be only allowed to receive call terminations in one of its HomeZones. The identification and location of the MS is ascertained prior to routing a call to the switching center serving the MS. The radio link between the serving switching center and the MS is maintained and used to terminate a call if the MS is determined to be within a HomeZone. The present invention eliminates the need to page a MS twice thereby speeding up the call termination. The MS provides its location area code and Cell ID to the serving/visited mobile switching center to facilitate the SCP identifying the MS's location prior to routing the call termination to the MS. The HomeZone call may be routed to a mobile station voicemail if it is determined to be outside its HomeZones, or, terminated to the mobile station but at a higher wireless billing rate. | 20,078 |
The present invention relates to novel beadlets of lipophilic nutrients and a process for their preparation. The present invention, particularly relates to novel and stable beadlets of lipophilic nutrients, materials, or substances, particularly nutrients like carotenoids, tocopherols, tocotrienols, plant sterols and stanols, and lecithins, select omega-3 fatty acids and poly-unsaturated fatty acids, more particularly novel beadlets of lutein, lutein esters, zeaxanthin, zeaxanthin esters, and a process for their preparation.
BACKGROUND OF THE INVENTION
The role of nutrients and phytochemicals in the promotion of good health through nutrition has now been extended to the likely benefits such as prevention of cancer, and protection against many other chronic diseases like arthritis, coronary heart disease, osteoporosis, and possibly many others.
A number of phytochemical nutrients have a lipophilic characteristic, such as tocopherols, tocotrienols, carotenoids, plant sterols and stanols, and lecithins, select omega-3 fatty acids and polyunsaturated fatty acids. The terms “lipophilic nutrient(s)” or “lipophilic phytochemical(s)” or “active lipophilic nutrient(s)” are interchangeably used for describing these compounds singly or in combination with other such compounds, while describing the current invention. Lipophilic nutrients are a class of substances which exhibit an affinity towards oily or fatty solvents or carriers. Lipophilic substances have a higher solubility in hydrocarbon solvents, such as hexane, and have poor water solubility.
Tocopherols, tocotrienols and carotenoids are naturally occurring lipophilic micronutrients, suggested to play a role in the prevention of several degenerative diseases. Plant sterols or stanols are naturally occurring lipophilic compounds structurally related to cholesterol found in nuts, vegetable oils, seeds, cereals and beans. Lecithins are complex lipophilic mixtures of glyceride oils and phosphatides (including phosphaptidylcholine, or PC) which are widely used in food-processing, and are now being used as dietary supplements for their possible role as a source of choline which is required for cell-membrane integrity and for a wide variety of biochemical and neurochemical processes within the body. Polyunsaturated fatty acids (such as linolenic acid, alpha-linolenic acid, and gamma-linolenic acid) and omega-3 fatty acids (such as AA, DHA and EPA) have a significant nutritional role to play with several metabolic processes and healthy body function.
Carotenoids and other lipophilic nutrients are useful as nutritional supplements for the prevention/treatment of diseases, such as, several forms of cancer, immunological disorders, eye disorders, skin manifestations, inflammation, cardio-vascular disease etc. These lipophilic nutrients are typically required to be administered daily through a suitable delivery system. There are several delivery systems such as emulsions and suspensions or oily solutions that are popularly used currently along with solid delivery forms such as gelatin beadlets.
Many of these lipophilic phytochemicals and nutrients are sought to be incorporated in formulations of nutritional supplements in a stable, standardized form. While these are typically available in oily, waxy or viscous form, there is often a need to present these in a dry delivery form, which provides standardized quantities of these phytochemicals with adequate protection against destabilizing influences of light, moisture or oxygen, or from contact with other reactive components of a multi-ingredient nutrient supplement or health food.
Issues in Formulating Products With Lipophilic Nutrients:
1. Difficulty in developing dry-delivery form:
Many nutritional formulations in the industry are in the form of tablets, capsules or dry-mixes. It is a major problem for formulators and manufacturers of such supplements to incorporate lipophilic nutrients such as carotenoids, vitamin E sources like tocopherols and tocotrienols, concentrated forms of PC-rich lecithins, phytosterols and plant stanols, various PUFA rich oils and omega-3 fatty acids singly or in combination with other nutrients into dry forms due to the oily, waxy or viscous nature of these products. Some options like spray dried powders, granules or gelatin beadlets work only with select products, and do not necessarily function well under tabletting systems. Some of the challenges in using lipophilic nutrients are explained below:
a. Carotenoids tend to be unstable at room temperature, and prone to degradation on exposure to light, heat, air and acidic environment. Their life needs to be extended by the use of other stabilizing anti-oxidants such as natural tocopherols, ascorbic acid derivatives and citrate. b. Another option for stabilizing carotenoids is by delivering the same in an oil medium to provide the protective cover of the oils along with naturally present, or added anti-oxidants. Dry delivery forms are considered more difficult to stabilize. c. Tocopherols and tocotrienols are typically found in an oily medium in the presence of vegetable oils. Such oily products are difficult to use except in the smallest of doses in dry delivery forms such as tablets without the use of specialized technologies to convert them to powders, granules or beadlets. d. Lecithins rich in the active ingredient PC (20-95%) tend to be viscous pastes or waxy masses which are not suitable for directly compressible or free-flowing powders. e. Phytosterols and plant stanols are oily products that have typically been supplemented through fat based supplements. Incorporating these into free flowing or directly compressible dry delivery forms would significantly increase the number of options for formulators and manufacturers of nutritional supplements. f. PUFAs, GLA and Omega-3 Fatty Acids are currently used sparingly and infrequently in tablet and capsule based supplements due to their oily nature. Conventional dry delivery conversion technologies do not provide good solutions for free flowing, directly compressible beadlets. 2. Difficulties in Stabilizing Lipophilic Nutrients:
By nature, carotenoids are unstable at room temperature. Their stability is affected by light, heat, air (oxygen) and acidic environment. It is known that their stability can be enhanced by the addition of certain stabilizing antioxidants such as natural tocopherols, ascorbic acid derivatives and citrate.
Carotenoids and other lipophilic nutrients are typically used as ingredients for nutritional supplement formulations either as dispersions in oil or as powders, granules or beadlets for making tablets or filling in capsules. In the form of oil dispersion, these nutrients are generally encapsulated in soft gelatin capsules. Some of these, such as carotenoids are also manufactured as cold water dispersible powder for use in fruit juices and other aqueous beverages. Out of these three forms, beadlets have the advantage of being suitable for further formulation into compressed tablets or encapsulated in hard gelatin capsules.
At present beadlets of carotenoids and other lipophilic nutrients are typically manufactured by spray drying a mixture of said active nutrients and gelatin along with sucrose, and stabilizers. In such beadlets the carotenoid/lipid particles are protected from light and oxygen in the matrix of gelatin and sucrose formed during the spray drying process in which matrix the carotenoid/lipoid particles are embedded. The spray-dried product is made less cohesive by covering with starch.
Processes for the preparation of beadlets have been described in numerous references. Dry formulations of fat soluble vitamins have been disclosed. Hahnlein et al. (U.S. Pat. No. 6,531,157). Starch-based emulsions have also been proposed as a mechanism for incorporating water-immiscible substances into a homogenous composition. Eskins et al. (U.S. Pat. No. 5,882,713). See also, e.g., U.S. Pat. No. 3,998,753; U.S. patent Application No. 2003/0064133, U.S. Pat. Nos. 4,254,100, 4,670,247, 4,929,774, 5,811,609, 6,093,348, 6,582,721, 5,849,345, and 6,663,900. Despite these methods, there remains a desire for a better way to formulate lipophilic substances into a stable, useable form. The beadlets obtained by the above known processes do not ensure stability to the active material either in the beadlet form itself, or when formulated into tablets. In addition, none of the hitherto known methods of making beadlets provide desirable physical characteristics, such as spherical, free flowing beadlets suitable for tabletting or capsule filling. Further, the beadlets produced by hitherto known methods do not prevent leaching of the active nutrients contained in such beadlets when subjected to compression to form tablets.
Most of these processes employ gelatin, a protein isolated from the bones and muscles of the animals. In recent times, use of excipients of animal origin in herb-based nutraceuticals is considered undesirable by a large section of users. Due to poor digestibility, use of gelatin based formulations have a limitation for use among the geriatric population. Sometimes, lactose is used as an excipient in the main beadlet matrix due to its compressible nature, but its dairy product (animal) origin makes it unacceptable to many, and is therefore considered to be undesirable.
At present, the nutraceutical industry needs:
a. a solid form of active ingredients (carotenoid and lipids), such as beadlets, suitable for formulation into tablet, b. beadlets from which the active ingredients do not leach out when compressed into tablets, c. beadlets which can be protected from light or oxygen or moisture, d. beadlets preferably free from excipients of animal origin (including dairy products), e. beadlets which can be produced conveniently using a simple process and equipment that are common, f. beadlets which have an appealing, uniformly spherical appearance.
Thus, the formulation of oral delivery systems for lipophilic nutrients, particularly carotenoids such as lutein, lycopene, beta carotene, present a challenge to the pharmaceutical and food industries, due to the oily nature and instability of the carotenoids/lipids.
By nature, carotenoids and lipophilic nutrients are unstable in presence of oxygen and light. Therefore, they can be stabilised by the incorporation of certain stabilising antioxidants. To further enhance stability, the active nutrients (e.g. carotenoids, or lipophilic nutrients such as tocopherols or tocotrienols etc) can be coated with polymer(s) that provide protection against the harmful effects of oxygen, light and moisture.
Non-pareil seeds such as sugar spheres or globules, without the active ingredient, on which the active ingredient is coated, are a convenient form for the preparation of oral dosage forms such as tablets or hard gelatin capsule, of the active ingredient. The beadlets produced by coating the active ingredient on the non-pareil seeds are uniformly spherical in nature and can be used in a size as small as about 250 microns. The active ingredient—loaded beadlets, having a generally spherical shape, may further be uniformly coated with a polymeric material to modify the release or mask the bitter taste of the drug.
In fluidisation process, the medium of coating can either be aqueous or organic. Attempts have been made in the past to apply fluid bed technology for preparing microcapsules of carotenoids using aqueous coating process on crystalline sucrose. Such processes suffer from drawbacks such as use of high temperature (180.deg. F), which are not suitable for many heat sensitive products such as carotenoids.
Unfortunately, this method using organic solvent medium is not applicable directly for the formation of beadlets of lipophilic nutrients, such as carotenoids, in spite of the above said advantages, due to their oily/waxy nature. Further these nutrients, when subjected to fluidization, form a cohesive mass, which adversely affects the fluidization. Therefore a process employing fluid-bed system using a non-aqueous coating medium has hitherto not been considered possible or demonstrated, for the preparation of beadlets of lipophilic nutrients such as carotenoids.
SUMMARY OF THE INVENTION
The present invention involves the coating of an inert core with lipophilic nutrients and/or stabilising antioxidants. The lipophilic nutrients and/or stabilising antioxidants can be supplied in an organic solvent medium and applied to the inert core by fluidisation technique. The resulting beadlets can be successfully employed in pharmaceutical and food industries.
According to the present invention, a process of coating an inert core with lipophilic materials or nutrients, particularly carotenoids, employing a fluidised bed technique in an organic solvent medium is possible. This was possible when we found that a solution of lipophilic nutrients, in a non-polar solvent when diluted with a polar solvent forms a colloidal suspension. This colloidal suspension when subjected to fluidisation using a fluid bed system employing an inert core did not form a cohesive mass and does not adversely affect the fluidisation process. On the contrary, the process resulted in the formation of inert cores uniformly coated with the lipophilic materials or nutrients in the form of uniformly spherical beadlets.
In other words, the fluidisation technique using a non-aqueous solvent which hitherto was not considered as applicable for the formation of beadlets of lipophilic nutrients, has been made possible by the process developed according to the present invention. This invention has resulted in developing a new concept enabling incorporation of oily lipophilic matter into beadlets.
The formation of stable, uniformly coated free flowing spherical beadlets of lipophilic nutrients is a result of the combination of the use of spherical inert cores (nonpareil seeds) and selected stabilising antioxidants and coating the resulting combination with oxygen and moisture barrier polymers to provide additional protection.
The stability of the beadlets of lipophilic nutrients achieved by this invention depends upon the judicious selection of the protective agents and coatings, and process conditions described in this invention. With the use of appropriate packing of the beadlets, such as sealed containers, by which exposure of the beadlets to moisture or air can be diminished or even eliminated, with commercially acceptable storage temperatures ranging from about 10 to about 30 degrees C., shelf life and stability of the actives for periods ranging from 6 months to 36 months, or higher as may be required- and tested as per ICH guidelines for the same-are possible.
The spherical nature of the beadlets has several advantages such as, free flowing property which is required during tablet compression, enables compression of tablets using a compression force as high as 10 kg/cm 2 , superior release property, possibility of site specific controlled release of carotenoids and lipids, and consequently, higher bioavailability. The major advantage of using such technology is that it avoids the use of high temperature (above 50 degree C.) during preparation of beadlets and thus prevents degradation of heat-sensitive bioactive compounds. Another advantage of using spherical cores is the broader range of beadlet size which can range between about 250 microns to about 3.50 mm. The beadlet size can also be from about 250 microns to about 2.0 mm. Another advantage of the present invention is that the invention can be practiced using existing fluid-bed technology and equipment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Accordingly, the present invention provides novel stable beadlets of lipophilic nutrients, which comprise an inert core having a coating of a mixture of stabilizing antioxidants and a lipophilic nutrient or mixtures thereof.
The novel beadlets of the present invention are obtained by coating one lipophilic nutrient, or a mixture of such nutrients on a central inert core to obtain uniform, generally spherical beadlets. The uniform, generally spherical, appearance of these beadlet provides excellent free flowing characteristics, which are very desirable for manufacturing and formulating operations. These novel beadlets are convenient to use, and have a stronger visual appeal. The novel beadlets of the present invention also may be stabilized synergistically with the use of anti-oxidants and with the application of layers of polymeric materials as coatings, preferably gelatin free, on the beadlets as barriers to prevent penetration of light, moisture and/or air. The beadlets of the present invention are well suited for use as directly compressible ingredients in tablets, or in two-piece capsules.
In one embodiment of the present invention the inert core may be comprised of any material that does not react with the lipophilic nutrient or carotenoid employed for coating. It can be selected from non-pareil seeds made of carbohydrates such as sugar, mannitol, starch, sago, or microcrystalline cellulose. More preferably, the core used may be seeds such as sugar spheres, mannitol spheres, or the like. The inert core can generally be in the form of a sphere, and can have a diameter from about 200 microns to about 3 mm and still yield a stable beadlet. The inert core can also have a diameter of about 200 microns to about 1.5 mm.
One embodiment of the current invention includes lipophilic nutrients in the coating. Lipophilic nutrients refers to a class of compounds that show an affinity towards oily or fatty solvents or carriers, such as hexane, or otherwise have a higher solubility in hydrocarbons than water, and may be used in the current invention. The beadlets can comprise from about 1 wt. % to about 50 wt. % lipophilic nutrient.
In one embodiment of the present invention the lipophilic nutrients used in the coating are carotenoids, tocopherols, tocotrienols, plant sterols and stanols, and lecithins, select omega-3 fatty acids, and poly-unsaturated fatty acids, or mixtures thereof. The lipophilic nutrients may comprise carotenoids such as lutein, lutein esters, zeaxanthin, alpha-carotene, beta-carotene, natural lutein or zeaxanthin esters, astaxanthin, or lycopene. The beadlets can contain a mixture of these substances as well. For instance, the stable beadlets can comprise xanthophyll esters containing lutein and zeaxanthin fatty acid esters in which about 90 wt. % to about 95 wt. % is trans-lutein esters, 0 wt. % to about 5 wt. % is cis-lutein esters and about 3.5 wt. % to about 6 wt. % is zeaxanthin esters. The beadlets can also comprise xanthophyll crystals that comprise at least about 85 wt. % total xanthophylls in which at least about 90 wt. % is trans-lutein and/or zeaxanthin.
The beadlets may also contain lipophilic nutrients such as vitamin A, vitamin D, or vitamin E in the form of mixed tocopherols or tocotrienols; vitamin K, medium chain triglycerides, and the like, or a mixture of such lipophilic nutrients. The lipophilic nutrients may also comprise lecithins such as mixtures of glyceride oils and phosphatides (including phosphaptidylcholine); plant stanols and/or sterols; polyunsaturated fatty acids such as linolenic acid, alpha-linolenic acid, and gamma-linoleic acid; omega-3 fatty acids such as AA, DHA and EPA; tocopherols such as α, β, χ, and γ tocopherols; tocotrienols such as α, β, χ, and γ tocotrienols; vegetable oils such as soya oil, partially or fully hydrogenated soya oil, cotton oil, coconut oil, palm-kernel oil, maize oil, palm oil, sunflower oil, olive oil, sesame oil, linseed oil, hazelnut oil, walnut oils, safflower oil, corn oil, peanut oil, vegetable oils having an unsaturated long chain fatty acid content of about 30 wt. % to about 90 wt. %, or any blends or fractions of these vegetable oils. The lipophilic nutrient can also be lipophilic substances that have diuretic and cosmetic application such as the oils of avocado, pear, blackcurrant, borage, castor, evening primrose, wheat-germ, and the like. Of course, the lipophilic nutrients can comprise combinations of the above ingredients. For instance, various lipophilic nutrients could be diluted using one or more of the above vegetable oils. One having ordinary skill in the art would understand that this list of potential lipophilic substances is not exhaustive, and there are many other lipophilic nutrients that offer medicinal, nutritional, pharmaceutical, or some other health or cosmetic benefit, which may also be utilized in the current invention.
In a preferred embodiment, the novel beadlets of the present invention may be in the form of spheres, globules and the like. The size of the beadlets of the present invention may range between about 250 microns to about 3.5 mm, more preferably about 250 microns to about 2.0 mm. By the term spherical, the inventors intend to describe the free flowing nature of the beadlets, and do not intend to mean a geometrically spherical beadlet. The generally spherical shape of the beadlets provides for a substantially free-flowing embodiment. The free-flowing capability of the beadlets can be determined by measuring the angle of repose. The angle of repose is determined by allowing the beadlets to drop from a funnel held at a certain height and form a conical heap on a level, flat surface. The angle of repose is the angle of the beadlet heap relative to the horizontal, flat plane. The beadlets of the invention have an angle of repose preferably between about 20 to about 30 degrees, more preferably about 22 to about 27 degrees, and most preferably between about 23 to about 25 degrees.
In another preferred embodiment of the present invention the novel beadlets may have a coating of a film of oxygen barrier polymer.
In another preferred embodiment of the present invention the novel beadlets may also have another coating, over the oxygen barrier polymer, with a film of a moisture barrier polymer. One with skill in the art will recognize that one coating may be used to provide both of these attributes.
In a preferred embodiment, the coatings are gelatin-free, and include only naturally derived materials. Such naturally derived materials can comprise components which can be derived or isolated from vegetables.
The polymer used for coating for providing protection to the lipophilic nutrient matrix against oxygen may be selected from hydroxy propyl cellulose, hydroxy propyl methyl cellulose, methacrylate copolymers, polyvinyl pyrrolidone, ethyl cellulose, carboxymethyl cellulose, polyvinyl alcohol, and the like, or their mixtures. Their amount may range from about 1 to about 40% of the weight of beadlets.
The polymer which can be used for providing a barrier to the entry of moisture can be selected from carboxy methyl cellulose sodium, hydroxy propyl cellulose, hydroxy propyl methyl cellulose, methacrylate copolymers, polyvinyl alcohol and the like. If present, the moisture barrier polymer can account for about 1% to about 40% of the weight of beadlets. The beadlets can also comprise about 2 wt. % to about 20 wt. % moisture barrier polymer. It should be understood that a single polymeric coating may act as both a moisture and oxygen barrier. Of course, two different coatings can be used to act as an oxygen barrier and as a moisture barrier, respectively.
The lipophilic nutrients can also be provided with stabilising antioxidants. Some stabilising antioxidants which may be employed to form the mixture of the lipophilic nutrients include vitamin E acetate, natural tocopherols, ascorbyl palmitate, ascorbic acid, sodium ascorbate, citric acid, rosemary extract or rosemary oil, curcuminoids, green tea extract, ginger extract, camosic acid, butylated hydroxy anisole, butylated hydroxy toluene and the like or their combinations thereof. When present, their amount used may vary from about 0.1% to about 20% by weight of the carotenoid, lipophilic nutrient, or lipid used. To ensure an even distribution in the beadlet, the lipophilic nutrient may be mixed with a stabilizing antioxidant prior to coating of the inert core.
The beadlets can contain other stabilisers, such as sorbic acid, sodium benzoate, sodium salicylate, EDTA, and the like or mixture thereof.
In another embodiment of the present invention there is provided a process for the preparation of the novel beadlets of lipophilic nutrients as defined above which comprises.
(i) forming a colloidal suspension of the desired lipophilic nutrients by dissolving the same in a non-polar solvent and diluting the resulting solution with a polar solvent. (ii) mixing the colloidal suspension obtained with a stabilising antioxidant, (iii) spraying the resulting colloidal suspension on to inert cores present in a fluid-bed system provided with a bottom spray mechanism, at a temperature in the range of ambient temperature to 45 degree C., at an atomisation pressure in the range of about 0.5 to about 3 Kg/cm 2 and a spray rate in the range of about 10 g/hour to about 600 g/hour, and (iv) drying the beadlets formed at an atomisation pressure of about 0.8 kg/cm 2 to about 1.2 kg/cm 2 .
In still another embodiment of the present invention there is provided a process for the preparation of the beadlets of lutein or any other carotenoid, which comprises:
(i) forming a colloidal suspension of desired carotenoid by dissolving the carotenoid in a non polar solvent and diluting the resulting solution with a polar solvent, (ii) mixing the colloidal suspension obtained with a stabilising antioxidant, (iii) spraying the resulting colloidal suspension on to inert cores present in a fluid-bed system provided with a bottom-spray mechanism at a temperature in the range of ambient temperature to about 45 degree C., at an atomisation pressure in the range of about 0.1 kg/cm 2 to about 3 kg/cm 2 and a spray rate in the range of about 10 g/hour to about 600 g/hour, and (iv) drying the resulting beadlets at an atomisation pressure of about 0.8 Kg/cm 2 to about 1.2 Kg/cm 2 .
Various parameters of this process can be modified. For instance, the colloidal suspension can be sprayed at a bed temperature from about 25 degree C. to about 40 degree C., or even from ambient temperature to about 32 degree C. In addition, the atomization pressure during spraying can be from about 0.5 kg/cm 2 to about 3 kg/cm 2 , or even from about 1.0 kg/cm 2 to about 2.5 kg/cm 2 .
In a preferred embodiment the non-polar solvents which may be used for preparing the colloidal suspension of the lipophilic nutrient include methylene chloride, chloroform, petroleum ether (low boiling), petroleum ether (high boiling) or mixtures thereof.
In another preferred embodiment, the polar solvents, which may be used for preparing the colloidal suspension of the lipophilic nutrient include isopropyl alcohol, acetone, methanol, ethanol, acetonitrile or mixtures thereof.
The non-polar solvent and polar solvent can be used in varying ratios. For instance, the non-polar and polar solvents can comprise a mixture of methylene chloride and isopropyl alcohol at a ratio of about 1:1 to about 0.1:1. The non-polar and polar solvents can also comprise a mixture of methylene chloride and isopropyl alcohol at a ratio of about 0.2:1 to about 2:1.
The lipophilic nutrients can be mixed with polar solvent directly. It may be noted that carotenoids or lipophilic nutrients are not completely soluble in polar solvent. This means that only some part of the carotenoid or lipophilic nutrient may form a suspension. This suspension may not be homogeneous due to the presence of large particles of the undispersed carotenoids or lipophilic nutrients. This suspension can be filtered to remove the solid materials and the resulting colloidal suspension can be used for the fluidisation process.
Although such a process is possible and envisaged within the broad scope of the present invention, the process is not economical and efficient. When carotenoids are mixed with polar solvent directly, some portion of the carotenoid forms colloidal suspension, where as a large portion remains as a lumpy, un-dispersed solid mass. One can filter such a mixture and use only the colloidal dispersion portion for coating. If one follows this procedure, it is not always possible to load an adequate quantity of carotenoid, and therefore not economical. Therefore it is desirable to first dissolve or disperse the carotenoid in non-polar solvent, and thereafter form a colloidal dispersion by the addition of polar solvent.
The stabilising antioxidants used may include vitamin E acetate, natural tocopherols, ascorbyl palmitate, ascorbic acid, sodium ascorbate, citric acid, rosemary extract or rosemary oil, curcuminoids, green tea extract, ginger extract, carnosic acid, butylated hydroxy anisole, butylated hydroxy toluene and the like or combinations thereof. When the stabilising antioxidants are used, the amount used may vary from about 0.1% to about 20% by weight of the carotenoid, lipophilic nutrient or lipid used. The stabilising oxidants may also contain other stabilisers which may include sorbic acid, sodium benzoate, sodium salicylate, EDTA, and the like or mixtures thereof.
Binding agents may be added along with the stabilising antioxidants for enhancing the efficiency of the coating. If used, the binding agents used may include gum acacia, gum tragacanth, xanthan gum, polyvinyl pyrrolidone, hydroxypropyl cellulose, hydroxypropyl methyl cellulose (5 cps), hydroxypropyl methyl cellulose (15 cps), cellulose or their mixtures. Their amount used may range from about 0.1% to about 10% of the weight of the beadlets. It may be advantageous to mix the binding agent with the colloidal suspension prior to spraying the suspension in the fluid-bed system.
Disintegrating agents may also be used along with the binding agents. If such agents are used they may be selected from starch, cross-linked polyvinyl pyrrolidone, cross-carmelose sodium and sodium starch glycolate or mixtures thereof. Their amount used may range from about 0.1% to about 5% of the weight of the beadlets. Disintegrating agents can also be combined with stabiliser. For instance, the beadlets can comprise from about 0.1 wt. % to about 20 wt. % stabiliser and/or disintegrating agent. Of course, the beadlets can contain stabiliser, binding agent, and disintegrating agent.
In another preferred embodiment of the present invention, the novel beadlets are provided with a coating of a layer of films of an oxygen barrier polymer.
In yet another preferred embodiment of the present invention, the novel beadlets are provided with another coating over the layer of the coating of films of an oxygen barrier polymer, with a film of a moisture barrier polymer.
The details of the invention are provided in the examples given below which are given for illustrative purposes only and therefore should not be construed to limit the scope of the invention which is defined by the claims.
EXAMPLES
Example 1
Preparation of Beadlets Containing Lutein From Petals of Marigold Flower
Step 1 Preparation of Xanthophyll Crystals
The preparation of xanthophyll esters concentrate is described in Indian Patent Application No. 622/Mas/2002, U.S. Pat. No. 6,737,535, and PCT/In 02/00219, the disclosures of which are incorporated by reference herein, and is summarized as follows.
Commercial grade marigold oleoresin (57.98 g) containing 11.54% xanthophyll content (by spectrophotometric method) was mixed with potassium isopropyl alcoholate (prepared by dissolving 15 g potassium hydroxide in 175 ml isopropanol.) The saponification mixture was heated and maintained at 70 degree C. for a period of 3 hours. The degree of hydrolysis was monitored by HPLC during the saponification stage. Isopropanol was distilled off under reduced pressure and the solids obtained were stirred with 230 ml of water at room temperature. The mixture was taken into a separatory funnel and extracted with equal volume of ethyl acetate (3 times). Ethyl acetate layer was collected and washed with distilled water for removing the excess alkali, soapy materials and other water-soluble impurities. The ethyl acetate layer was distilled off under reduced pressure to get saponified crude extract (25.01 g).
This resultant crude extract (25.01 g) was subjected to purification by stirring with 100 ml of hexane/acetone mixture (80:20) at room temperature for 30 minutes, followed by filtration. The precipitate of xanthophyll crystals obtained was washed with methanol. The resulting orange crystals were vacuum dried at ambient temperature for 72 hrs.
The yield of the xanthophyll crystals was 3.41% (1.98 g). Xanthophyll content was 86.23% by weight (as determined by UV/Vis spectrophotometry) out of which the contents of trans-lutein, zeaxanthin, and other carotenoids were 91.43%, 6.40% and 2.17% respectively as determined by HPLC analysis.
Step 2-Conversion of Above Xanthophyll Crystals to Beadlets
Carotenoids in the form of Xanthophyll crystals as described in step 1 a above (92 g, containing 86.23% Xanthophylls by weight (78.84% trans-lutein) were suspended in a mixture of 300 g isopropyl alcohol and 800 g methylene chloride. A solution of 10 gm of Hydroxypropylmethyl cellulose (5 cps) in 200 g isopropyl alcohol and 100 g methylene chloride was added to the above suspension along with 20 g natural tocopherol, 40 g ascorbyl palmitate and 15 g sodium starch glycolate. The suspension was strained through 100 mesh filter.
300 g of non-pareil seeds made of sugar, were charged into a Uni-Glatt fluid bed processor with bottom spray, and warmed for 30 minutes at 35 degree C. The carotenoids suspension as prepared above was sprayed on the non-pareil seeds at the rate of 500 g/hour. The bed temperature was maintained at 35 degree C. Atomization pressure of 1.2 kg/cm 2 was maintained. 470 g of carotenoid loaded beadlets showing 9.46% trans-lutein were obtained.
80 g of polymer mixture comprising 32 g of ethyl cellulose and 48 g of hydroxypropyl methyl cellulose was dissolved in solvent mixture comprising 500 g of methylene chloride and 1000 g of isopropanol. 8 g of polyethylene glycol 600 was added as plasticiser. With this solution the coating was performed on carotenoid loaded non-pareil seeds in UniGlatt fluid bed coater using bottom spray technology at a spray rate of 400 g per hour. An atomization speed of 1.2 kg/cm 2 was maintained. Bed temperature of 38 degree C. was maintained through out the coating process. 540 g of oxygen-barrier coated beadlets showing 8.51% trans-lutein content were obtained.
55 g of polyvinyl alcohol was dissolved in 300 g water, mixed with 6 g of polyethylene glycol 400 and 2 g of titanium dioxide and the mixture was sprayed on oxygen-barrier coated non-pareil seeds using Uni-Glatt fluid-bed coater using bottom spray mechanism. A bed temperature of 45 degree C. was maintained during coating. Atomisation pressure of 1.5 kg/cm 2 was maintained. A spray rate of 150 g/hour was used. 580 g of moisture barrier coated carotenoid beadlets showing 6.8% trans-lutein content were obtained.
Example 2
Preparation of beadlets containing Free Lutein in Oil Suspension from petals of Marigold Flower
Lutemax® Free Lutein Oil Suspension (obtained from Marigold flower petals) (110 g free lutein oil suspension in 220 g safflower oil) was suspended in a mixture of 150 g isopropyl alcohol and 800 g chloroform. A solution of 5 gm of hydroxypropylmethyl cellulose (15 cps) in 200 g isopropyl alcohol and 100 g methylene chloride was added to the above suspension along with 20 g natural tocopherol, 40 g ascorbyl palmitate and 15 g sodium starch glycolate. The suspension was strained through 100 mesh filter.
250 g of non-pareil seeds made of sugar, were charged into a Uni-Glatt fluid bed processor with bottom-spray, and warmed for 30 minutes at 35 degree C. The carotenoid suspension as prepared above was sprayed on the non-pareil seeds at the rate of 500 g/hour. The bed temperature was maintained at 35 degree C. Atomisation pressure of 1.2 kg/cm 2 was maintained. 510 g of carotenoid loaded beadlets showing 8.1% trans-lutein were obtained.
80 g of polymer mixture comprising 10 g of ethyl cellulose and 70 g of hydroxypropyl methyl cellulose was dissolved in solvent mixture comprising 500 g of methylene chloride and 1000 g of isopropyl alcohol, 8 g of polyethylene glycol 600 was added as plasticiser. With this solution the coating was performed on carotenoid loaded non-pareil seeds in Uni-Glatt fluid bed coater using bottom spray technology at a spray rate of 400 g per hour. An atomization speed of 1.2 kg/cm 2 was maintained. Bed temperature of 38 degree C. was maintained through out the coating process. 580 g of oxygen-barrier coated beadlets showing 7.2% trans-lutein content were obtained.
60 g of sodium carboxymethyl cellulose dissolved in 300 g water, then mixed with 6 g of Polyethylene glycol 400 and 2 g of titanium dioxide was sprayed on oxygen-barrier coated non-pareil seeds using Uni-Glatt fluid-bed coater using bottom spray mechanism. A bed temperature of 45 degrees C. was maintained during coating. Atomisation pressure of 1.5 kg/cm2 was maintained. A spray rate of 150 g/hour was used. 610 g of moisture barrier coated carotenoid beadlets showing 6.5% trans-lutein content were obtained.
Example 3
Preparation of Beadlets Containing Lutein from Petals of Marigold Flower
Lutemax® Free Lutein (92 g, containing 78.84% trans-lutein) was suspended in a mixture of 100 g isopropyl alcohol and 900 g methylene chloride. A solution of 80 gm of polyvinyl pyrrolidone in 400 g isopropyl alcohol and 100 g methylene chloride was added to the above suspension along with 20 g natural tocopherol, 40 g ascorbyl palmitate and 15 g sodium starch glycolate. The suspension was strained through 100 mesh filter.
300 g of non-pareil seeds made of sugar, were charged in to a Uni-Glatt fluid bed processor with bottom spray, and warmed for 30 minutes at 35 degree C. The carotenoid suspension as prepared above was sprayed on the non-pareil seeds at the rate of 500 g/hour. The bed temperature was maintained at 35 degree C. Atomisation pressure of 1.2 kg/cm 2 was maintained. 550 g of carotenoid loaded beadlets showing 9% trans-lutein were obtained.
80 g of polymer mixture comprising 32 g of ethyl cellulose and 48 g of hydroxypropyl methyl cellulose was dissolved in solvent mixture comprising 500 g of methylene chloride and 1000 g of isopropanol. 8 g of polyethylene glycol 600 was added as plasticiser. With this solution the coating was performed on carotenoid loaded non-pareil seeds in Uni-Glatt fluid bed coater using bottom spray technology at a spray rate of 400 g per hour. An atomization speed of 1.2 kg/cm 2 was maintained. Bed temperature of 38 degree C. was maintained through out the coating process. 600 g of oxygen-barrier coated beadlets showing 7.9% trans-lutein content were obtained.
60 g of sodium carboxymethyl cellulose dissolved in 300 g water, then mixed with 6 g of Polyethylene glycol 400 and 2 g of titanium dioxide was sprayed on oxygen-barrier coated non-pareil seeds using Uni-Glatt fluid-bed coater using bottom spray mechanism. A bed temperature of 45 degree C. was maintained during coating. Atomisation pressure of 1.5 kg/cm 2 was maintained. A spray rate of 150 g/hour was used. 650 g of moisture barrier coated carotenoid beadlets showing 6.6% trans-lutein content were obtained.
Example 4
Preparation of Beadlets Containing 25% Trans-Lutein from Petals of Marigold Flower
Marigold extract (382 g, containing 75% trans-lutein) was suspended in a mixture of 1200 g isopropyl alcohol and 2800 g methylene chloride. A solution of 90 gm of hydroxypropylmethyl cellulose (5 cps) in 500 g isopropyl alcohol and 200 g methylene chloride was added to the above suspension along with 60 g natural tocopherol, 80 g ascorbyl palmitate and 15 g cross-carmellose. The suspension was strained through 100 mesh filter.
300 g of non-pareil seeds made of sugar, were charged in to a Uni-Glatt fluid bed processor with bottom spray, and warmed for 30 minutes at 35 degree C. The carotenoid suspension as prepared above was sprayed on the non-pareil seeds at the rate of 500 g/hour. The bed temperature was maintained at 35 degree C. Atomisation pressure of 2 kg/cm 2 was maintained. 910 g of carotenoid loaded beadlets showing 29% trans-lutein were obtained.
75 g of polymer mixture comprising 32 g of ethyl cellulose and 48 g of hydroxypropyl methyl cellulose was dissolved in solvent mixture comprising 500 g of methylene chloride and 1000 g of methanol. 8 g of polyethylene glycol 600 was added as plasticiser. With this solution the coating was performed on carotenoid loaded non-pareil seeds in Uni-Glatt fluid bed coater using bottom spray technology at a spray rate of 400 g per hour. An atomization speed of 2.2 kg/cm 2 was maintained. Bed temperature of 38 degree C. was maintained through out the coating process. 985 g of oxygen-barrier coated beadlets showing 27.1% trans-lutein content were obtained.
65 g of polyvinyl alcohol dissolved in 300 g water, then mixed with 6 g of Polyethylene glycol 400 and 2 g of titanium dioxide was sprayed on oxygen-barrier coated non-pareil seeds using Uni-Glatt fluid-bed coater using bottom spray mechanism. A bed temperature of 45 degree C. was maintained during coating. Atomisation pressure of 2.5 kg/cm 2 was maintained. A spray rate of 150 g/hour was used. 1040 g of moisture barrier coated carotenoid beadlets showing 25.7% trans-lutein content were obtained.
Example 5
Step 1
Preparation Of Xanthophyll Esters Concentrate
The preparation of xanthophyll esters concentrate is described in Indian Patent Application No. 420/Mas/2002, U.S. Pat. No. 6,737,535, and PCT/In 02/00218, the disclosures of which are incorporated by reference herein, and is summarized as follows.
A weighed quantity of marigold oleoresin (150.3 g) with xanthophyll ester content 23.10% and trans-lutein, cis-lutein and zeaxanthin area percentage by HPLC 67.23, 22.08 and 5.18 respectively was transferred into an Erlenmeyer flask (1000 ml) followed by the addition of 750 ml of 2-propanone. This was stirred using a thermostatically controlled stirrer at 15 degree C. to 25 degree C. for a period of 5-10 hours. After an interval of every 2 hours sample was drawn, filtered and the dried precipitated material was analyzed for the ester content and trans-: cis-ratio by HPLC. Finally when the desired degree of the purity had been achieved the solution containing precipitate was filtered through a Buchner funnel and the precipitate was dried in vacuum drier at ambient temperature.
The yield of the resulting concentrate was 20.10 g (13.37%) and the analysis showed xanthophyll ester content 59.26% assayed by spectrophotometric method, measuring at 474 nm. This xanthophyll esters concentrate contained area percentage by HPLC, trans-lutein 92.71, cis-lutein 1.40 and zeaxanthin 5.11 respectively. On visual examination, this concentrate showed an improved orange red color as compared to the starting material, which is dark brown in color.
Step 2. Preparation of Beadlets Containing Xanthophyll Esters and Trans-Lutein Esters from Petals of Marigold Flower
Xanthophyll esters concentrate (160 g, containing 59.26% xanthophylls esters by weight-yielding 27.47% trans-lutein on hydrolysis) was suspended in a mixture of 700 g isopropyl alcohol and 600 g methylene chloride. A solution of 80 gm of hydroxypropylmethyl cellulose (15 cps) in 400 g isopropyl alcohol and 100 g methylene chloride was added to the above suspension along with 20 g natural tocopherol, 40 g ascorbyl palmitate and 20 g sodium starch glycolate. The suspension was strained through 100 mesh filter.
320 g of non-pareil seeds made of sugar, were charged in to a Uni-Glatt fluid bed processor with bottom spray, and warmed for 30 minutes at 35 degree C. The carotenoid suspension as prepared above was sprayed on the non-pareil seeds at the rate of 500 g/hour. The bed temperature was maintained at 35 degree C. Atomisation pressure of 1.2 kg/cm 2 was maintained. 600 g of carotenoid loaded beadlets showing 10.1% trans-lutein were obtained.
80 g of polymer mixture comprising 10 g of ethyl cellulose and 70 g of hydroxypropyl methyl cellulose was dissolved in solvent mixture comprising 500 g of methylene chloride and 1000 g of isopropanol. 8 g of polyethylene glycol 600 was added as plasticiser. With this solution the coating was performed on carotenoid loaded non-pareil seeds in Uni-Glatt fluid bed coater using bottom spray technology at a spray rate of 400 g per hour. An atomization speed of 1.2 kg/cm 2 was maintained. Bed temperature of 38 degree C. was maintained through out the coating process. 680 g of oxygen-barrier coated beadlets showing 8.67% trans-lutein content were obtained.
150 g of polyvinyl alcohol dissolved in 300 g water, then mixed with 6 g of polyethylene glycol 400 and 2 g of titanium dioxide was sprayed on oxygen-barrier coated non-pareil seeds using Uni-Glatt fluid-bed coater using bottom spray mechanism. A bed temperature of 45 degree C. was maintained during coating. Atomisation pressure of 1.5 kg/cm 2 was maintained. A spray rate of 150 g/hour was used. 810 g of moisture barrier coated carotenoid beadlets showing 6.0% trans-lutein content were obtained.
Example 6
Preparation of Beadlets Containing Beta-Carotene
Beta-carotene (20% dispersion in palm oil) 160 g, was suspended in a mixture of 900 g isopropyl alcohol and 800 g chloroform. A solution of 80 gm of polyvinyl pyrrolidone in 400 g isopropyl alcohol and 100 g methylene chloride was added to the above suspension along with 20 g natural tocopherol, 40 g ascorbyl palmitate and 12 g. starch. The suspension was strained through 100 mesh filter.
450 g of non-pareil seeds made of sugar, were charged in to a Uni-Glatt fluid bed processor with bottom spray, and warmed for 30 minutes at 35 degree C. The carotenoid suspension as prepared above was sprayed on the non-pareil seeds at the rate of 500 g/hour. The bed temperature was maintained at 35 degree C. Atomisation pressure of 1.2 kg/cm 2 was maintained. 650 g of carotenoid loaded beadlets were obtained.
74 g of polymer mixture comprising 10 g of ethyl cellulose and 70 g of hydroxypropyl methyl cellulose was dissolved in solvent mixture comprising 500 g of methylene chloride and 1000 g of methanol. 8 g of polyethylene glycol 600 was added as plasticiser. With this solution the coating was performed on carotenoid loaded non-pareil seeds in Uni-Glatt fluid bed coater using bottom spray technology at a spray rate of 400 g per hour. An atomization speed of 1.2 kg/cm 2 was maintained. Bed temperature of 38 degree C. was maintained through out the coating process. 680 g of oxygen-barrier coated beadlets were obtained.
145 g of sodium carboxymethyl cellulose dissolved in 300 g water, then mixed with 6 g of polyethylene glycol 400 and 2 g of titanium dioxide was sprayed on oxygen-barrier coated non-pareil seeds using Uni-Glatt fluid-bed coater using bottom spray mechanism. A bed temperature of 45 degree C. was maintained during coating. Atomisation pressure of 1.5 kg/cm 2 was maintained. A spray rate of 150 g hour was used. 810 g of moisture barrier coated carotenoid beadlets were obtained.
Example 7
Preparation of Beadlets Containing Lecithin
Lecithin (Epikuron 200, made by Degussa Bioactives, containing 95% phosphatidylcholine) 120 g, was dissolved in a mixture of 700 g ethanol and 800 g chloroform. A solution of 45 g of hydroxy propyl cellulose in 400 g isopropyl alcohol and 100 g methylene chloride was added to the above suspension along with 25 g cross-linked polyvinyl pyrrolidone. The suspension was strained through 100 mesh filter.
500 g of non-pareil seeds made of sugar, were charged in to a Uni-Glatt fluid bed processor with bottom spray, and warmed for 30 minutes at 35 degree C. The mixture suspension as prepared above was sprayed on the non-pareil seeds at the rate of 500 g/hour. The bed temperature was maintained at 35 degrees C. Atomisation pressure of 2.9 kg/cm 2 was maintained. 680 g of lecithin loaded beadlets were obtained.
60 g of polymer mixture comprising 10 g of ethyl cellulose and 70 g of hydroxypropyl methyl cellulose was dissolved in solvent mixture comprising 500 g of methylene chloride and 1000 g of isopropyl alcohol. 8 g of polyethylene glycol 600 was added as plasticiser. With this solution the coating was performed on carotenoid loaded non-pareil seeds in Uni-Glatt fluid bed coater using bottom spray technology at a spray rate of 400 g per hour. An atomization speed of 3 kg/cm 2 was maintained. Bed temperature of 45 degree C. was maintained through out the coating process. 740 g of oxygen-barrier coated beadlets were obtained.
120 g of sodium carboxymethyl cellulose dissolved in 300 g water, then mixed with 6 g of polyethylene glycol 400 and 2 g of titanium dioxide was sprayed on oxygen-barrier coated non-pareil seeds using Uni-Glatt fluid-bed coater using bottom spray mechanism. A bed temperature of 45 degree C. was maintained during coating. Atomisation pressure of 1.5 kg/cm 2 was maintained. A spray rate of 150 g/hour was used. 850 g of moisture barrier coated lecithin beadlets were obtained.
Example 8
Preparation of Beadlets Containing Natural Mixed Tocopherol in Vegetable Oil
Natural tocopherols in sunflower oil (Tocoblend L50) 80 g, was suspended in a mixture of 900 g isopropyl alcohol and 800 g chloroform. A solution of 80 g of polyvinyl pyrrolidone in 400 g isopropyl alcohol and 100 g methylene chloride was added to the above suspension along with 40 g ascorbyl palmitate and 12 g starch. The suspension was strained through 100 mesh filter.
400 g of non-pareil seeds made of sugar, were charged into a Uni-Glatt fluid bed processor with bottom spray, and warmed for 30 minutes at 35 degree C. The mixture as prepared above was sprayed on the non-pareil seeds at the rate of 500 g/hour. The bed temperature was maintained at 35 degree C. Atomisation pressure of 1.2 kg/cm 2 was maintained. 580 g of natural tocopherol loaded beadlets were obtained.
70 g of polymer mixture comprising 10 g of ethyl cellulose and 70 g of hydroxypropyl methyl cellulose was dissolved in solvent mixture comprising 500 g of methylene chloride and 1000 g of isopropyl alcohol. 8 g of polyethylene glycol 600 was added as plasticiser. With this solution the coating was performed on carotenoid loaded non-pareil seeds in Uni-Glatt fluid bed coater using bottom spray technology at a spray rate of 400 g per hour. An atomization speed of 1.2 kg/cm 2 was maintained. Bed temperature of 38 degree C. was maintained through out the coating process. 650 g of oxygen-barrier coated beadlets were obtained.
130 g of sodium carboxymethyl cellulose dissolved in 300 g water, then mixed with 6 g of Polyethylene glycol 400 and 2 g of titanium dioxide was sprayed on oxygen-barrier coated Non-pareil seeds using Uni-Glatt fluid-bed coater using bottom spray mechanism. A bed temperature of 45 degree C. was maintained during coating. Atomisation pressure of 1.5 kg/cm 2 was maintained. A spray rate of 150 g/hour was used. 650 g of moisture barrier coated mixed tocopherol beadlets were obtained.
Example 9
Preparation of Beadlets Containing Soy Bean Oil
Soya bean oil, 120 g, was suspended in a mixture of 400 g isopropyl alcohol and 800 g chloroform. A solution of 80 gm of polyvinyl pyrrolidone in 400 g isopropyl alcohol and 100 g methylene chloride was added to the above suspension along with 12 g of starch. The suspension was strained through 100 mesh filter.
400 g of non-pareil seeds made of sugar, were charged in to a Uni-Glatt fluid bed processor with bottom spray, and warmed for 30 minutes at 35 degree C. The mixture as prepared above was sprayed on the non-pareil seeds at the rate of 500 g/hour. The bed temperature was maintained at 35 degree C. Atomisation pressure of 1.2 kg/cm 2 was maintained. 590 g of soy oil loaded beadlets were obtained.
70 g of polymer mixture comprising 10 g of ethyl cellulose and 70 g of hydroxypropyl methyl cellulose was dissolved in solvent mixture comprising 500 g of methylene chloride and 1000 g isopropyl alcohol, 8 g of polyethylene glycol 600 was added as plasticiser. With this solution the coating was performed on oil-loaded non-pareil seeds in Uni-Glatt fluid bed coater using bottom spray technology at a spray rate of 400 g per hour. An atomization speed of 1.2 kg/cm 2 was maintained. Bed temperature of 38 degree C. was maintained through out the coating process. 650 g of oxygen-barrier coated beadlets were obtained.
130 g of sodium carboxymethyl cellulose dissolved in 300 g water, then mixed with 6 g of polyethylene glycol 400 and 2 g of titanium dioxide was sprayed on oxygen-barrier coated non-pareil seeds using Uni-Glatt fluid-bed coater using bottom spray mechanism. A bed temperature of 45 degree C. was maintained during coating. Atomisation pressure of 1.5 kg/cm 2 was maintained. A spray rate of 150 g/hour was used. 770 g of moisture barrier coated soy oil beadlets were obtained.
Preparation and Evaluation of Tablet Formulation of Beadlets
The beadlets of present invention (Examples 1-4) 32 g were mixed with dicalcium phosphate 40 g, microcrystalline cellulose 20 g, sodium starch glycolate 2 g, hydroxypropyl cellulose 3 g, aerosil 1 g and talcum 1 g. After uniform blending the powder mixture was compressed into tablets of 500 mg weight with hardness of 10 kg/cm 2 .
TABLE 1
Properties of tablets compressed with beadlets of invention
Tablet
Dissolution
Beadlet
Angle of
Disintegration
rate,
sample no.
Repose
time, in minutes
Friability, %.
%
Product of
23 degrees
0.5
0.4
71.5
Example 1
Product of
25 degrees
0.6
0.35
70.6
Example 2
Product of
24 degrees
0.3
0.6
72.8
Example 3
Product of
24 degrees
1.2
0.5
73
Example 4
Product of
25 degrees
1.3
0.4
71.8
Example 5
The flow property of the beadlets was assessed by determining the angle of repose under the method disclosed in Remington's Pharmaceutical Sciences, 16th Ed., page 1545. The current invention can include beadlets having an angle of repose between about 22 to about 27 degrees. Beadlets having an angle of repose between about 23 to about 25 degrees exhibit excellent flow properties. Accordingly, the beadlets can be formed to have an angle of repose between about 23 to about 25 degrees.
The tablets showed disintegration time, as determined by the procedure given in United States Pharmacopoeia USP23 page no. 1790, of less than 2 minutes and friability, as determined by procedure given in USP 23 page no 1981, of less than 1%. The dissolution rate was determined by procedure given in USP 23 page no. 1791. The tablets showed dissolution rate of more than 70%. When scored tablets were examined under scanning electron microscopy, the beadlets were found to be spherical and intact. The cross-section beadlets recovered from the tablet when examined under scanning electron microscopy revealed that the polymer coatings could withstand the compression force during tabletting and are in intact condition. No leaching of carotenoids into the tablet matrix was visible.
Stability Studies
The beadlet formulations of Example 1-4 were subjected to accelerated stability studies at 40 degree C. and 75% relative humidity. The beadlets were analyzed for carotenoid content before and after 6 months. The result of the study is shown in the following Table 2.
TABLE 2
Accelerated Stability of Beadlets at 40 Degree C. and at 75% Relative
Humidity (RH)
Beadlet
Initial analysis
Final analysis
Percent retention of
sample
t-lutein
t-lutein
t-lutein
Example 1
6.8%
6.6%
97.05%
Example 2
6.5%
6.35%
97.69%
Example 3
6.6%
6.48%
98.18%
Example 4
25.7%
24.8%
96.5%
Example 5
6.0%
5.92%
98.66%
The above study concludes that the beadlets prepared by the present invention provide adequate stability to the carotenoid contained inside. | The invention disclosed in this application relates to novel stable beadlets of lipophilic nutrients comprising an inert core having a coating of stabilizing antioxidants, lipophilic nutrients, or mixtures thereof. The beadlets may be coated with one or more coatings to protect the lipophilic ingredients from the atmosphere, specifically the coatings can be used to protect against moisture and/or oxygen. The invention also relates to a process for the preparation of the stable beadlets. The beadlets can be used in medicines and dietary supplements intended to facilitate the reduced risk of macular degeneration, cataract, and several forms of cancer. | 60,185 |
FIELD OF THE INVENTION
The invention is concerned with a method and with a device for continuously detecting at least one substance in the gaseous or liquid mixture by means of a sensor electrode to which a variable potential is applied.
BACKGROUND OF THE INVENTION
The demand for a problem-free, rapid and cost-effective detection method for substances, especially for harmful substances, has increased recently, one of the reasons being the increased demands for environmental protection. In order to comply with harmful-substance limiting values (for example, in controlling and reducing emissions) it is necessary to be able to detect harmful substance concentrations in gaseous or liquid media reliably and continuously, possibly by the use of electrochemical sensors. In process monitoring, too, the control of the concentration of products, starting materials and impurities may be necessary for optimum performance of the process. However, rapid detection is made difficult by the fact that the materials or substances are frequently slow to react.
Frequently, electrochemical detection is based on the amperometric principle and is aimed at the quantitative detection of a material component.
For this purpose, substances (Cl 2 , HCl, SO 2 , NO x , H 2 CO, etc.) are reacted electrochemically, that is, by an oxidation or reduction reaction on a sensor electrode to which a constant potential is applied.
The current flowing can be set in relation to the concentration of the substance to be detected. The selectivity of a sensor electrode based on this working principle is limited by the electrode material used and by the potential that can be applied to the electrode. The potential that can be applied is limited to a range of values at which the oxygen of the air is not reduced and/or the electrolyte for the substance to be detected is not decomposed. Namely, the currents produced by these perturbing effects would overlap the actual measured signal almost completely. Moreover, some substances are not sufficiently reacted in the available potential range or poison the sensor electrode by adsorption, so that they cannot be detected by this method. These substances include many unsaturated compounds, halogenated hydrocarbons and aromatics.
Qualitative and quantitative electrochemical detection can be achieved by voltametric techniques. Here, the substance to be detected is not reacted at the electrode at a fixed potential. Rather, oxidation or reduction of the substance is catalyzed successively while a continuously varying potential is applied. The recorded relationship between the amount of charge passing through or current and applied potential can be correlated with the quantity and also with the nature of the substance to be detected.
In another electrochemical detection method, called the alternating current method, an alternating voltage is superimposed on the voltage applied to an electrode. The alternating current flowing through is measured. The measured alternating current is shifted in phase with respect to the applied alternating potential, namely, because of the electrode capacitance, which is changed by the adsorption of the substance to be detected and also because of oxidation and reduction processes. Therefore, a complex resistance is defined, which is called impedance below, which describes the processes on the electrode surface appropriately. Its frequency-dependent and potential-dependent real and imaginary parts give information about the concentration of the substance to be detected.
A detection method, which is similar to the alternating-current method is tensametry, known from the analysis for solutions (see for example Nürnberg et al., in Methodicum Chimicum, Volume 1/1, Stuttgart 1973). However, in such methods, the sample with the substance to be detected must always “be prepared” manually to some extent, that is, interfering impurities must be removed and the oxygen of the air must be excluded.
Thus, continuous detection cannot be performed with these two known methods—alternating-current method and tensametry.
In this connection, the determination of concentration of blood glucose is also known (Kasapbasioglu et. al., Sensors and Actuators B, 13-14 (1993), p. 749). Here, glucose is oxidized directly electrochemically to gluconic acid on a membrane-covered electrode made of a noble metal. The electrode functions as an electrocatalyst, to which a potential program that decreases and increases stepwise is applied. At each step, an alternating potential with a high frequency and one with a low frequency are superimposed onto the potential. The glucose concentration in the blood is determined from the resulting real and imaginary part of the impedance at certain potential steps.
Furthermore, it is known that the selectivity and sensitivity of an electrode can be increased in an electrochemical detection method by utilizing the adsorption or absorption of the substance to be detected on the electrode surface. The adsorption or absorption can be supported, weakened or eliminated by the applied potential or potential program. The substance to be detected is adsorbed at a potential at which the substance is not electro-chemically active. The amount adsorbed as a function of time is then correlated with the concentration of the substance to be detected.
A method is known from the technical journal “Sensors and Actuators B”, Ege et al., 4 (1991), p. 519, with which the reactive carbon monoxide CO in a CO/H 2 mixture can be detected quantitatively based on the amperometric principle. For the detection, first the carbon monoxide component is adsorbed on a platinum electrode and then reacted electro-chemically. The carbon monoxide is adsorbed specifically at a potential at which it is not electrochemically active or is not reacted. After adsorption of the carbon monoxide to the saturation value, the potential is increased to a value at which the carbon monoxide is oxidized. The amount of charge flowing during oxidation is measured and is integrated over the oxidation time. The measured signal thus obtained is correlated with the concentration of the carbon monoxide. However, the amount of charge flowing is additionally superimposed by amounts of charge stemming from the electrochemical reaction of additionally adsorbed substances, such as oxygen. This additional amount of flowing current is determined in another reference cycle, in order to correct the measured signal. In this reference cycle, a potential is applied over a very short period of time to adsorb the additionally adsorbed substances. The time period is made so short that the carbon monoxide is not adsorbed on the electrode surface of the sensor. Then the potential is brought to a suitable value for the electrochemical reaction of these additionally adsorbed substances. The amount of charge flowing during this electrochemical reaction is used as correction value, because it is influenced only by the additionally adsorbed substances. Minimum CO concentrations up to 0.05% CO can be detected in a CO/H 2 mixture. However, this known method cannot provide continuous detection either. Moreover, there is no suitable sensor for the commercial utilization of this method of detection.
Similarly, the reactive carbon dioxide, CO 2 , can be detected quantitatively in air at concentrations from 5% to 0.3% CO 2 (Küver et al.; J. Electroanal. Chem., 353 (1993), p. 255).
It is also known that several substances can be detected quantitatively simultaneously with the aid of a chain of electrodes which mostly consist of different electrode materials. Different potentials are applied to the individual electrodes and one substance reacts electrochemically at each of these potentials. The measured signals obtained at the individual electrodes are correlated with the individual substance concentrations using pattern recognition technology.
The electrochemical detection methods mentioned above are not suitable for rapid, continuous, both qualitative as well as quantitative detection, or are very expensive. Moreover, substances with low reactivity cannot be detected with these known detection methods or can only be detected at high concentrations.
In general, known electrochemical detection methods are characterized by the fact that the selectivity is frequently too low. Similarly, most of the sensors based on these detection methods do not satisfy the general criteria of a sensor: The detection should occur rapidly and continuously without preparation of the sample “on location” with a time constant of the order of one or at most a few minutes. In addition, the sensor should operate in the ambient atmosphere, that is, generally in the presence of the oxygen of air and should also be cost-effective.
The goal of the invention is to provide further methods and devices for continuous and quantitative as well as qualitative detection of substances in gaseous or liquid mixtures.
SUMMARY OF THE DISCLOSURE
In accordance with another aspect of the invention, a method is provided for the continuous detection of a substance in a gaseous or liquid mixture, with the aid of a sensor electrode to which a variable potential is applied, in which method the substance is enriched at the surface of the sensor electrode, the enrichment is determined with the aid of measurement of the electrode capacitance of the sensor electrode, the measured value thus obtained is correlated with the substance and then the substance enriched on the surface of the sensor electrode is removed. In accordance with another aspect of the invention, a device suitable for carrying out the above-described method is provided with means for carrying out the individual process steps listed above.
The detection method described above is designated below as a modified alternating-current method. Here, the applied potential is preferably chosen in such a way that the substance is enriched on the electrode surface of the sensor without an electrochemical reaction. The ions of the electrolyte form a double layer at the sensor electrode. Together with the electrode surface of the sensor, this double layer acts as a type of plate capacitor. The degree of enrichment of the substance changes the capacitance of this plate capacitor or sensor electrode by the adsorbate blocking a part of the electrode surface. The capacitance of the sensor electrode can be followed with the aid of a suitable electronic measurement method and correlated with the concentration of the substance. This modified alternating current method is characterized by high sensitivity to changes in the structure of the double layer. Thus, it is especially suitable for simple qualitative and quantitative detection of small concentrations of surface-active substances, especially halogenated hydrocarbons and highly volatile organic solvents.
First of all, it could be shown that the substance to be detected is adsorbed in spite of simultaneous reduction of the oxygen of the air (even when the concentration of the oxygen of the air is greater by a factor of 10 5 to 10 6 or even more than the concentration of the substance to be detected) and, thus, the electrode capacitance—and hence also the concentration of the substance to be detected—can be detected with the reduction of oxygen occurring simultaneously.
The enrichment of one or several substances present in a mixture can be influenced among others by the adsorption time and the applied adsorption potential. The adsorption time of a substance depends on different thermodynamic and kinetic properties of the various substances in the mixture. By suitable selection of the applied adsorption potential and other parameters (see below), the substance can be detected selectively in the mixture.
With the modified detection method, the disadvantages of the known detection methods described above are avoided. The method is universally applicable, especially to substances with low reactivity.
In a preferred embodiment, the electrode capacitance of the sensor electrode is determined by an impedance measurement. Preferably, a dc voltage with a superimposed low-frequency alternating voltage is applied to the sensor electrode for this purpose. The impedance of the sensor electrode or of the double layer is then determined based on the phase shift and the change of amplitude of the alternating current flowing as a result of the applied low-frequency alternating voltage.
Preferably, the frequency of the low-frequency alternating voltage is optimized with reference to the impedance measurements.
In a preferred detection method, the concentration of the substance is determined based on the difference of the electrode capacitance of the sensor electrodes, with and without enrichment of the substance on the electrode surface. Here, preferably in a first step, a dc voltage with a superimposed alternating voltage is applied to the sensor electrode as potential. The potential is chosen so that the substance is reacted electrochemically and therefore is not enriched. Thus, in this first step, the electrode surface is activated. Then the electrode capacitance is measured with the electrode surface being activated or free. In a second step, the potential is preferably brought to a value at which the substance to be detected is enriched at the electrode surface of the sensor and remains there essentially unreacted. Then the electrode capacitance is measured with the electrode surface being occupied. The concentration value of the substance to be detected is calculated from the difference of the electrode capacitances measured in the two steps.
In an especially preferred detection method, the concentration of the substance is determined based on the change of the capacitance of the sensor electrode as a function of time. The change of the electrode capacitance as a function of time can be measured quasi-differentially—at successive points in time during the enrichment process—or as an average—measuring it at the beginning and at the end of the enrichment phase. It is proportional to the time change of the imaginary part of the alternating current caused by the applied low-frequency alternating voltage. This flowing alternating current can be measured by a simple technology. Thus, the time change of the electrode capacitance and the concomitant enrichment of the substance at the electrode surface can be followed advantageously almost continuously. This time change is then correlated with the substance concentration using known relationships, for example, calibration, which is carried out once during manufacture or at large time intervals.
The parameters measured in this detection method—for example, enrichment time, enrichment potential and frequency of the applied alternating voltage—provide sufficient possible combinations for accurate, simple, qualitative and quantitative detection of substances in a gaseous or liquid mixture, especially at low concentrations.
Preferably, in order to remove the substance enriched at the electrode surface, the potential is brought to a potential characteristic for its electrochemical reaction and/or desorption. For the purpose of continuous detection, it is necessary that the electrode surface of the sensor used be freed completely of the enriched substance from time to time. This can be done with the aid of the so-called oxidation cycles. Here, the electrode surface is cleaned and activated by appropriate selection of the applied potential by first electrochemically reacting and/or desorbing the enriched substance or by displacing it with adsorbed oxygen. Finally, the reacted substance or the adsorbed oxygen is desorbed completely, for example, by reducing the potential or by other methods.
Furthermore, the enrichment is preferably ended when the measured electrode capacitance or the time change of the electrode capacitance of the sensor electrode reaches a predetermined value. Hereby, advantageously, the occupation of the electrode surface with the substance to be enriched is followed. Using a predetermined value, the relationship of the response time to the sensitivity of the sensor can be varied. The response time depends automatically on the time during which the substance to be detected is enriched on the electrode surface to an amount which is sufficient for the measured signal to be evaluated. With the predetermined value, thus the sensor performs the detection at maximum sensor sensitivity and minimum response time. The reactivity and sensitivity of the sensor can thus be optimized advantageously and especially simply.
Preferably, the measured value thus obtained is optionally normalized using a measured value obtained through at least one other measurement of the electrode capacitance of the sensor electrode, in which step essentially not the substance to be detected, but only oxygen or hydrogen is enriched at the sensor electrode. Thus, for this normalization, the additional measured value can be a measured value that is obtained either in a separate measurement or—when measuring the time change of the electrode capacitance as an average—it can be the value measured at the beginning of the enrichment phase. With this normalization, the alterations, aging or wear phenomena of the electrode surface are advantageously taken into consideration and the measured signal is appropriately corrected. The normalization is based on the fact that adsorption of pure oxygen or hydrogen on the sensor electrode is influenced adversely by the quality of the sensor electrode surface to the same extent as the enrichment of the substance to be detected. Preferably, the measured value can also be normalized with the aid of the electrode capacitance.
According to another aspect of the invention, a method is provided for the continuous detection of a substance in a liquid mixture with the aid of a sensor electrode to which a variable potential is applied, by enriching the substance on the surface of the sensor electrode, then bringing the potential to a potential value which is characteristic for the electrochemical reaction of the substance, measuring the current thus produced and correlating the obtained measured value with the substance. In accordance with another aspect of the invention, a device is provided for carrying out the method described above, with means which carry out the individual process steps listed above.
The detection method described in the preceding paragraph will be called below the liquid-phase potential method. With this liquid phase potential method at least one substance is detected in a liquid phase. Similarly to the modified alternating-current method, it also uses the enrichment of the substance to be detected on an electrode surface to which an appropriate potential is applied. After enrichment, preferably, the enriched substance is oxidized or reduced at a potential characteristic for the electrochemical reaction. The current resulting from the electrochemical reaction is then correlated with the enriched substance and finally with the substance concentration in the liquid phase or solution to be investigated. With the aid of the enrichment, the local substance concentration near the sensor electrode is highly increased, so that the current flowing during the subsequent electrochemical reaction provides a larger measured signal. A sensor to be used in this liquid-phase potential method thus advantageously also detects substances with low reactivity, because this sensor is overall more sensitive than the known sensors. Furthermore, this sensor can be optimized through the parameters of enrichment potential and enrichment time.
According to still another aspect of the invention, a method is provided for the continuous detection of at least two substances in a gaseous or liquid mixture with the aid of a sensor electrode to which a variable potential is applied, in which method at least two detection cycles are performed and at least one substance is enriched at the surface of the sensor electrode per detection cycle, after which the potential is brought to a potential characteristic for the electrochemical reaction of at least one substance and the current produced thereby is measured, and, subsequently, the measured values thus obtained are correlated with the substance. In accordance with another aspect of the invention, a device is provided for carrying out the method described above, with means which carry out the individual process steps listed above.
The detection method described in the preceding paragraph will be referred to below as the general potential method. It serves for the detection of at least two substances in a gaseous or liquid mixture. For this purpose, the potential applied to the sensor electrode goes through a given potential program in each detection cycle.
The potential program can be the following: first a potential is applied at which at least one of the substances is enriched at the electrode surface, whereby the time available for the enrichment is preferably variable. Then the potential is changed to a value at which at least one of the substances enriched on the sensor electrode is reacted electrochemically. The current flowing during this process is measured. The potential is changed, preferably by a jump, to a value at which again at least one substance is enriched at the electrode surface of the sensor. For the detection of several substances in a mixture, in this special potential program, as many enrichment steps must be carried out as many different substances are to be detected. At least one substance is reacted electrochemically in each of these enrichment steps.
For example, in the detection of two substances in a two-substance mixture, in the second enrichment step, additionally, the substance which is not enriched in the first enrichment step is additionally enriched. When both substances were enriched in the first enrichment step at the electrode surface, then, in the second enrichment step, a potential is applied at which only one of the two substances is enriched. After the particular enrichment steps, a potential is applied at which the enriched substance or substances are reacted electrochemically. The current flowing during this time is determined.
In case of three substances to be determined, for example, the potential program can be the following: when, in a first enrichment step, substances 1 , 2 and 3 are enriched, and in a second step substances 1 and 2 are enriched, then, in this special potential program, in a third step either only substance 1 or substance 2 may be enriched. Enrichment of substance 3 does not lead to an appropriate independent detection of all three substances.
However, alternatively, the potential program can also be the following: first a potential is applied at which only one or several substances is/are enriched. Then, the individual substances are reacted or oxidized at characteristic potentials (when more than two substances to be detected are present, several enrichment steps can also be performed; however, for this purpose, the number of enrichment steps does not have to be as many as the number of substances to be detected contained in the sample).
The currents flowing at the different electrochemical reactions are used to determine the concentrations of the particular substances.
With this potential program, the cross-sensitivity of a sensor can be advantageously highly minimized. In addition, the detection of several substances can be done in the presence of the others advantageously, using only one sensor cell, instead of one sensor cell for each substance to be detected, as done in the prior art. The enrichment with continuous detection also provides the advantage that the sensor selectivity can be optimized via the enrichment potential and the enrichment time.
With these two potential methods according to the invention (liquid phase and general), the disadvantages of the known detection methods of the prior art can be avoided. They are universally applicable, especially to substances with low reactivity.
The variable potential can be altered cyclically in all three detection methods according to the invention. After completion of a potential program with enrichments and subsequent electrochemical reactions, the potential is brought again to the initial value of the same potential program and is thus available for the next detection cycle. Accordingly, in this way, the concentration of at least one substance to be detected can be followed quasi-continuously.
In order to maintain the sensitivity of the sensor electrode through a continuous detection operation, the electrode surface must be freed, in an appropriate desorption step, both from the oxidized and reduced enriched layer of the substance to be detected as well as from the additionally adsorbed oxygen layer (or also hydrogen layer). For this purpose, in a first step, preferably the enrichment layer is oxidized and an oxygen layer is enriched. In the next desorption step, preferably, a low potential is applied to the sensor electrode for a short time during which the enriched oxygen layer is reduced (optionally, the entire enrichment layer is desorbed). Then the potential is again brought to the potential that is characteristic for the electrochemical reaction. Repeated passage through these desorption steps ensures that the electrode surface is actually unoccupied. Additionally, the sensor electrode can be activated by adsorbing oxygen in a first step and desorbing it again in a second step.
In another practical example of a continuous detection method, the potential which is characteristic for the electrochemical reaction is changed linearly in time. For this purpose, after the enrichment step, the potential is brought to a potential value, preferably in a jump, and then varied linearly as a function of time. Thus, the potential goes through a range at a given potential change rate. Due to the sudden change of the potential values, one obtains an enrichment step which is accurately defined in time and also the time for this enrichment step and thus for the entire detection cycle is shortened. This value of the potential change rate has an upper limit by the fact that the electrochemically reacted substances should find sufficient time to desorb. The potential change rate should not be chosen too slow, because otherwise the response time of the sensor would be increased. Owing to the linear increase of the potential from an initial value to an end value, all substances that are reacted between these two electrochemical values are advantageously desorbed from the electrode surface.
Furthermore, the concentration of the substance is determined preferably through the current produced by the electrochemical reaction at a specific potential. Preferably, for this purpose, the maximum current flowing during the electrochemical reaction is determined instead of the current integrated in time over the entire electrochemical reaction and is thus correlated with the enriched substance concentration. The measured current can be correlated with the substance concentration using a previously performed calibration.
Preferably, the measured value(s) obtained with the above detection method is/are correlated with a measured value, called oxygen value below, in which the oxygen value is obtained through at least one other detection cycle—called reference cycle below—in which the substance is not enriched in a first step on the sensor electrode. If said potential values are in ranges in which other substances which perturb the detection are reacted electrochemically or enriched simultaneously, then the additionally flowing currents must be taken into consideration in reference cycles in the determination of the substance concentrations. These interfering substances are present in the electrolyte initially, such as bound oxygen or water. During the reference cycle, no substance is enriched, for example, only oxygen is adsorbed. Then the oxygen is oxidized or reduced at the same potential at which the substance to be detected was already reacted electrochemically and the current flowing during this process is determined. For the purpose of measurement value correction, the current measured in the reference cycle is subtracted from the current measured in a normal detection cycle.
In this method, the measured value thus obtained is preferably normalized to the oxygen value determined in the reference cycle. With this normalization, changes, alterations or wear phenomena of the electrode surface are taken into consideration advantageously and the measured signal corrected correspondingly. The normalization is based on the fact that pure oxygen or hydrogen adsorption is influenced adversely to the same extent by the quality of the sensor electrode surface as the enrichment of the substance to be enriched on the sensor electrode. Preferably, the measured values are also normalized with the aid of the electrode capacitance.
Especially preferably, during the potential method according to the invention (liquid phase and general), the electrode capacitance is measured and the enrichment ended when the electrode capacitance or the time change of the electrode capacitance reaches a predetermined value. In this detection method—called combined detection method below—in principle, the potential method (liquid phase and general) according to the invention, is combined with the modified alternating current method according to the invention. The enrichment is followed as in the modified alternating current method. The electrochemical reaction is started only when a sufficient amount of substance has become enriched on the electrode surface. The resulting oxidation current thus yields a sufficiently large measurement signal and thus concomitantly a reliable concentration result for the substance to be detected. Preferably the concentrations of the individual substances to be detected are determined only through the enrichment, and the determination of the other substances is carried out either in combination, through a previous enrichment and subsequent electrochemical reaction, or directly through an electrochemical reaction.
In another preferred variation of the modified alternating current method or potential method (liquid phase, general or combined), the substance to be detected is first reacted electrochemically at the sensor electrode or at another electrode at an applied potential and at least one product thus obtained is then detected by the sensor electrode. If a substance to be detected is characterized by a small tendency to become enriched at the sensor electrode used, then this substance can advantageously be reacted electrochemically at an electrode at a given potential to form an intermediate product. The intermediate product formed should then be able to be enriched at the electrode surface of the sensor electrode at another potential value. The final detection of this intermediate product is then carried out either through the modified alternating current method presented above or by one of the potential methods. Preferably, the electrode necessary for the production of the intermediate product can be separated in space from the sensor electrode, so that the substance that has a low tendency to become enriched can be detected continuously. The spatial separation must not be too large, so that the intermediate product can diffuse from the separate electrode to the sensor electrode within a short time—preferably in fractions of a minute.
Preferably, the detection can be optimized through the parameters of electrode material, electrolyte composition, enrichment, enrichment potential, potential for electrochemical reaction and/or time change of the potential for the electrochemical reaction. The detection methods according to the invention provide a multiplicity of optimization parameters for a highly sensitive and selective sensor electrode. The optimization parameters for the enrichment—enrichment time, enrichment potential, electrode material and electrolyte composition—as well as for the electrochemical reaction—electrolyte composition, electrode material, characteristic potential and its time change—can vary.
In the devices according to the invention, the sensor electrode is preferably a membrane provided with an electrocatalyst on one side. The sensor electrode is wetted mostly on one side with the electrolyte solution necessary for the electrochemical detection. The electrolyte solution is preferably hygroscopic, so that evaporation of the water is largely avoided and that its composition—concentration of the conducting salt—remains as constant as possible. Preferably, the membrane is made of teflon and/or the electrocatalyst is a thin platinum, rhodium or palladium layer applied by sputtering. Platinum is characterized by good enrichment properties toward a number of substances, while palladium is especially suitable for the detection of saturated halogenated hydrocarbons. However, other metals of the platinum group can also be used as electrocatalyst.
The test liquid itself can replace the electrolyte solution for the liquid detection method. Here, the membrane is preferably prepared from a porous, hydrophilic or ion-conducting material (for example, Nafion), and the electrocatalyst is applied onto the side that faces the test liquid—and not the electrolyte liquid. For this purpose, the electrocatalyst is applied in such a thin layer that the membrane with the electrocatalyst is still porous or ion-conducting. Furthermore, the sample liquid side of the membrane can be provided with a thin Nafion or cellulose acetate film, as protecting film. With this structure, the sensor electrode can be used relatively universally in various (even nonaqueous or poorly conducting) liquids.
For the gaseous detection method, the electrocatalyst is sputtered onto the side of the membrane which faces the electrolyte solution. Here, the gaseous substances to be detected can diffuse through the membrane and the electrocatalyst and dissolve in the electrolyte solution before they reach the electrode surface. However, for the gaseous detection method, the sensor electrode described above for the liquid detection method may also be used.
The invention complex will be explained in more detail below with the aid of practical examples and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates, in a schematic representation, a cross-section through a sensor, where the sensor electrode is also shown in detail as a model;
FIG. 2 illustrates, an equivalent circuit for the behavior of the sensor electrode with enriched substance in the modified alternating current method;
FIG. 3 a is a diagram of a potential-time curve for the modified alternating-current method;
FIG. 3 b is a diagram of the corresponding time curve of the imaginary part of the alternating current;
FIG. 4 a is a diagram of a potential-time curve for the liquid phase potential method for the qualitative and quantitative detection of a substance;
FIG. 4 b is a diagram of a corresponding current-time curve;
FIG. 5 is a diagram of a potential-time curve for the general potential method for the qualitative and quantitative detection of two substances;
FIG. 6 a is a diagram of a potential-time curve for the combined detection method;
FIG. 6 b is a diagram of a corresponding time curve of the imaginary part of the alternating current; and
FIG. 6 c is a diagram of a corresponding dc current—time curve.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows in a schematic representation a cross-section through a sensor generally designated 2 , which is suitable for carrying out the represented detection method of substances in gaseous mixtures.
The core part of sensor 2 is a sensor electrode 4 consisting of a teflon membrane 6 , shown schematically in detail in an enlarged form. The teflon membrane 6 preferably has a thickness of 75 μm, a pore size of 0.2 μm and a diameter of 6 mm. It separates the gaseous mixture with the substance to be detected from an electrolyte solution necessary for the electrochemical detection. The electrolyte solution is selected to be strongly hygroscopic (for example, perchloric or sulfuric acid) and thus prevents rapid drying of sensor 2 , so that the electrolyte concentration in the inner space of sensor 2 hardly changes at all. The teflon membrane 6 is sputtered with an electrocatalyst 8 (for example, platinum) on the side facing the electrolyte solution. A thin, noble metal layer with a layer thickness of preferably 90 nm is produced. In addition, the roughness factor of the noble metal layer is reduced considerably in comparison to the roughness factor of known sensor electrodes for amperometric detection methods. The teflon membrane 6 thus modified functions at the same time as a sensor and as a gas-diffusion electrode. It is secured tightly to a sensor housing 12 , with the aid of a pressing disk 10 through an O-ring 11 . The sensor electrode 4 is dimensioned in such a way that, on the one hand, edge effects (interfering electrochemical processes at the edge or in the electrolyte gaps at the seal) become negligible, while, on the other hand, the resistance of the metal layer toward the center of the sensor electrode becomes sufficiently small. The resistance is measured here from the edge of the sensor electrode 4 where the electrical contact to an external electronic is provided, to the center of the sensor electrode 4 , where the electrochemical processes occur mainly—such as enrichment and electrochemical reaction, etc.
The sensor electrode 4 is embedded into the cylindrical sensor housing 12 in such a way that it and an opposite counter-electrode 14 , as components of a three-electrode arrangement, close this inner sensor housing 12 tightly at the open sides. The counter-electrode 14 is pressed tightly against sensor housing 12 with the aid of a ring 16 , a means to secure against turning and an O-ring 17 . Preferably, a reference electrode 18 , for example, a hydrogen electrode, is introduced through a conical bore 20 into the cylinder wall of sensor housing 12 , so that it can be placed in the immediate vicinity of the sensor electrode 4 . The sensor 2 can be filled with electrolyte solution through another conical bore 22 . This bore 22 is then closed for the practical operation of sensor 2 , in order to prevent running out of the electrolyte solution. Optionally, the gaseous products that are formed in the electrolyte solution or the gases that are formed at the counter-electrode 14 can be liberated directly through the porous teflon membrane 6 , as long as their amount, based on the area of the teflon membrane 6 , is not too large. Therefore, the area of the teflon membrane 6 must be greater than the area of the sensor electrode 4 or of the electrocatalyst. Thin wires 24 a and 24 b provide the electrical contact of sensor electrode 4 and counter-electrode 14 toward the outside.
In order to provide good tightness or a high pressing pressure of sensor 2 , the sensor housing 12 is surrounded by a steel mantle 26 , which presses the sensor housing 12 together under pressure, with the aid of leaf springs 28 and a lock nut 30 .
The gaseous mixture with the substance(s) to be detected enters through an opening 31 of the steel mantle 26 and the pressing disk 10 in the direction shown by the arrow and impinges onto the outside of the porous teflon membrane 6 . From there, it goes through the pores of the teflon membrane 6 inside sensor housing 12 and dissolves in the electrolyte solution located there.
The sensor 2 , together with the corresponding electronics for carrying out the individual detection methods according to the invention (potential program, automatic ending of the enrichment phase, etc.), can be dimensioned in such a way that it is easily transportable. For this purpose, the heavy steel mantle 26 can be replaced by another suitable housing.
Overall, the sensor 2 has good contact between the thin wires 24 a and 24 b and the respective electrocatalyst layer of sensor electrode 4 or counter-electrode 14 , especially with regard to a small distance of the reference electrode from the working electrode, has small dimensions; a special type of the sensor electrode 4 as well as a small roughness factor of the electro-catalyst layer were optimized for the detection method of the invention.
FIG. 2 shows an equivalent circuit for the electrical behavior of sensor electrode 4 , counter-electrode 14 and reference electrode 18 in the modified alternating current method.
Ions and solvent molecules with dipole character (that is, water molecules) interact with the metallic electrode surface 8 of sensor electrode 4 and of counter-electrode 14 and develop an electrolytic double layer there. In the simplest case, this electrolytic double layer behaves as a plate capacitor 32 a or 32 b with a certain double-layer capacitance. This double-layer capacitance includes in principle all electrostatic interactions of the ions (sulfate ions, etc.) and solvent molecules with the sensor electrode.
If a potential is applied between the sensor electrode 4 and the reference electrode 18 in order to enrich the substance, then the substance can be converted to an adsorbate such as
C 2 Cl 4 +4 e − →(C 2 ) ads. +4Cl − between 0-0.3 V
This adsorbate can consist of ions as well as neutral molecules with and without dipole character and forms an additional adsorbate layer on the particular electrode surface. This adsorbate layer blocks the sensor electrode 4 where it is adsorbed. Then at those places, the double-layer capacitance is reduced significantly because the distance of the double layer from the electrode surface is enlarged as a result of the adsorbate located in between.
In addition to the conversion of the substance to be detected to the adsorbate, in case of enrichment of the substance, at the same time, a competing electrochemical reaction can also occur, such as
C 2 Cl 4 +6H + +10 e − →C 2 H 6 +4Cl − between 0-0.2 V
Even at an optimum adsorption potential, possibly to a small extent, an undesirable competing electrochemical reaction of the substance to be detected can occur to a product which is no longer adsorbed. Furthermore, at potentials for the adsorption of the substance to be enriched, the oxygen of the air is also reduced, which leads to a large additional current which is highly superimposed onto the actual measured signal. These electrochemical reactions that occur parallel to the adsorption, are described with the aid of resistors 40 a and 40 b.
In addition to the double layer capacitance, another pseudocapacitance 34 a and 34 b also arises at the particular electrodes 4 and 14 , due to the following effect: protons from the solution adsorb as hydrogen on the electrocatalyst 8 —and the following reaction occurs on a platinum layer:
Pt+H + +e →←Pt−H (respectively: H + +e − →←H ad )
The current flowing as a result of this behaves exactly as a capacitive current, and, therefore, we speak of a pseudocapacitance 34 a or 34 b . This pseudocapacitance 34 a or 34 b is highly potential-dependent and is an order of magnitude larger than the actual double layer capacitance 32 a or 32 b . At the point of the sensor electrode 4 , where the substance to be detected is adsorbed (irreversibly), no hydrogen can adsorb any longer, as a result of which, in addition to the double layer capacitance (see above), the pseudocapacitance 34 a or 34 b is also reduced.
Resistors 36 a and 36 b describe the limited rate of hydrogen adsorption. However, this rate is extremely high and the resistors 36 a and 36 b are thus correspondingly small, so that the double layer capacitances 32 a and 32 b as well as the pseudocapacitances 34 a and 34 b can hardly be distinguished from one another.
Instead of hydrogen adsorption, the adsorption of metal ions, such as copper, can also be utilized according to
Cu 2+ +2 e − ⇄Cu ads.
Since some of the substances to be detected prevent the adsorption of copper, in this way, the selectivity of sensor 2 can be increased. In this case, the value of the resistors 36 a and 36 b must be taken into consideration.
The reference electrode 18 is described by a complex impedance 18 a . However, this impedance 18 a , similarly to the current flowing through it, is so low that no potential drop occurs.
The ohmic resistance of the electrolyte solution before the particular electrode 4 and 14 is represented by an electrolyte resistor 38 a and 38 b . The ohmic resistance of the particular electrocatalyst layer is represented by the corresponding resistors 42 a and 42 b . However, it cannot be distinguished from the ohmic resistance of the electrolyte solution by technical measurements.
With the aid of the equivalent circuit shown in FIG. 2, the double layer capacitance (optionally also the pseudocapacitance) are derived from the measured impedance of the sensor electrode 4 through the imaginary part of the alternating current and correlated with the enrichment or with the time change of the enrichment. Then, from the time-dependent amount of enrichment, the concentration and the type of enriched substance can be determined.
FIG. 3 a shows a diagram of a potential-time curve for the modified alternating current method using the detection of perchloroethylene in synthetic air as example. FIG. 3 b shows a corresponding time plot of the alternating current imaginary part called alternating current transient A′ below. In FIGS. 3 a and b , the ordinate gives the potential in volts and the imaginary part of the alternating current in milliamperes and the abscissa shows the time in seconds. The electrode surface is a platinum layer in this example and the electrolyte solution contains 1 M HClO 4 as supporting electrolyte.
In the first detection step Z (FIG. 3 a )—also called desorption Z below—the electrode surface is freed from any impurities present using an oxidation-reduction reaction and is activated. For this purpose, the potential applied to the sensor electrode 4 is increased or decreased to values at which any substances adhering to the electrode surface are reacted electrochemically and desorbed.
In a second detection step A—also called enrichment A below—a dc potential is applied at which, when possible, no electrochemical reaction of the substance to be detected is catalyzed in the neighborhood of the electrode, but rather, as selectively as possible, the substance to be detected is enriched. The accurate value for this potential depends on the thermodynamic and kinetic properties of the substance to be enriched. The enrichment rate is also dependent on the applied potential. For example, perchloroethylene becomes enriched as a potential value of 100 mV with a high rate of enrichment.
In the modified alternating current method, during enrichment A, an alternating voltage with an amplitude of 10 mV and a frequency of 10 Hz is superimposed onto the dc potential. The alternating current flowing A′ (FIG. 3 b ) is recorded by the sensor electronics as a measured signal. For the evaluation of the measured signal, the initial drop of the alternating current transient A′ is taken, is related to the enrichment rate and this is correlated with the concentration of the enriched substance. As can be seen in FIGS. 3 a and b , the beginning of enrichment A and the use of a constant alternating current transient A′ are shifted in time with respect to one another, which is caused by the process of establishment of the enrichment potential, by the electrolyte resistance or also by the measurement technology. This modified alternating current method is characterized by high linearity within the measured signal and substance concentration, because the enrichment rate can be measured almost directly and can be represented as a simple function of the concentration.
After the enrichment A, desorption steps Z are performed in order to desorb the enriched substance as completely as possible from the electrode surface via an oxidation or reduction reaction. After the fifth desorption step Z, consequently, the sensor electrode is sufficiently purified and, at the same time, activated again.
The amount of enriched substance contributes significantly to the sensitivity of sensor 2 . In order to ensure that sensor 2 is equally sensitive, even at different substance concentrations, the alternating current transient A′ is followed during the entire enrichment A and whether or not a sufficient amount of substance has been enriched is derived from this.
FIG. 4 a shows a diagram of a potential-time curve for one of the potential methods for the selective quantitative detection of the substance to be detected. In the diagram, the ordinate gives the potential in volts and the abscissa shows the time in seconds. The potential-time curve is shown for the example of a detection of benzene in the liquid phase (as well as in the gaseous phase) on a sensor electrode 4 sputtered with platinum.
In a first detection step, the enrichment step A, a potential of 200 to 300 mV is applied at sensor electrode 4 for 20 seconds in order to enrich a certain amount of the substance to be detected. As it is known from heterogeneous catalysis, here the internal bonds of the enriched or adsorbed substance are weakened. A subsequent oxidation can then occur at lower potentials than that needed for the oxidation of a free, that is, not adsorbed substance. During the enrichment or adsorption of the substance, oxygen of the air is reduced simultaneously. This leads to a large negative current (not shown) at sensor electrode 4 , but this has no influence on the detection process.
In a second detection step B—also called potential jump B below—the potential is changed suddenly to 900 mV. This potential value is chosen so that oxidation of the enriched substance or layer just does not occur.
In a third detection step C—also called oxidation C below—the potential is increased linearly in time with a potential change rate of 300 mV/s. Hereby, the enriched layer becomes oxidized and at the same time, largely desorbed—for example, benzene becomes oxidized at platinum electrodes according to
(C 6 H 6 ) ads .+12H 2 O→6CO 2 +30 e − +30H + .
At potentials higher than about 0.7 V, additionally, the oxygen bound in the electrolyte liquid begins to adsorb:
H 2 O→O ads. +2 e + 2H + .
Here, a clearly defined oxide layer is formed as a monolayer. In some cases, the already adsorbed substance to be detected (benzene) and now to be reacted electrochemically, is to be displaced at sensor electrode 4 :
(C 6 H 6 ) ads. +H 2 O→C 6 H 6 +O ads. +2H + +2 e − .
The potential steps serve to achieve oxidation and desorption of the enrich ed substance as completely as possible.
In a fourth detection step D—also called reduction D below—the potential is reduced again to a highly cathodic potential of 50 mV for a fraction of a second (for example, 0.5 sec); this potential corresponds approximately to the enrichment potential. The time for the fourth detection step D is chosen to be so short that the substance to be detected cannot be deposited on the electrode surface again and, on the other hand, the entire oxide layer will be reduced and desorbed.
The three detection steps, B, C and D, that is, the potential jump B, oxidation C and reduction D form a detection cycle E. This detection cycle E is repeated five times in succession. As a result of this, the substance to be detected and additionally enriched substances are removed completely from the electrode surface until finally only the clearly defined oxide covering layer that is formed again in the detection cycle E remains. It can be assumed that no enriched substance is present on the electrode surface any longer in the fifth detection cycle E.
FIG. 4 b shows a diagram of the current-time curve, which flows as a result of the potential program shown in FIG. 4 a . In the diagram, the ordinate gives the current in milliamperes and the abscissa gives the time in seconds.
The current-time curve shows a current peak B′ and a subsequent oxidation current C′ for each detection cycle E of the potential-time curve.
The current peak B′ occurs during the potential jump B and results from the recharging of the produced double layer at the sensor electrode 4 .
The oxidation current C′ increases strongly to a maximum, which is at the highest potential value of the potential range of oxidation C in the practical example shown in FIG. 4 b . This maximum can also be reached at a different value of the potential of the potential range. The oxidation current C′ results from a superimposition of two currents, one of which flows because of the oxidation C of the substances to be detected, enriched and additionally enriched and the other flows because of the development of the oxide layer on the electrode surface. The maximum of the oxidation current C′ decreases steadily from the first to the fifth detection cycle E. In the fifth detection cycle E, the magnitude of the current that flows due to the oxidation C of the enriched substances is so small that only the development of the oxide layer contributes to the oxidation current C′. For example, in the example of benzene, the oxidation current C′ is measured at 1.44 V.
A measured signal to be correlated to the concentration is obtained, for example, by forming the difference between the measured oxidation currents C′ in the first and in the fifth detection cycles E. The potential at which these two oxidation currents C′ are measured within a detection cycle E can be chosen in such a way that the resulting difference is maximum. In this example, the difference of the maximum values of the oxidation currents C′ is formed.
The enrichment of a substance at the electrode surface is influenced significantly by the properties of this surface. Thus, the obtained measured signal should be suitably normalized in order to be able to be reproduced well. For this normalization, the difference of the oxidation currents C′ in the first and in the fifth detection cycles E is formed and normalized to the oxidation current C′ determined in the fifth detection cycle E. The oxidation current C′ measured in the fifth detection cycle E reflects the real surface conditions that influence the enrichment conditions. After this normalization, the measured signal is a dimensionless quantity.
The sensitivity of sensor 2 is greatly improved by enrichment A. The oxidation current C′, which flows during the electrochemical reaction of the enriched substance, which is to be correlated with the concentration, is dependent on the amount of substance accumulated during the enrichment A. Thus, the measured signal is influenced considerably by the amount of time available for the enrichment A. This time can also be optimized automatically by measuring the electrode capacitance. For this purpose, the enrichment potential is applied only until the electrode capacitance reaches a predetermined value. For the detection of benzene, concentrations to 1 ppm can be detected reliably. (For example, perchloroethylene can be detected to 30 ppm, but with an improved evaluation electronics even to 3 ppm.)
The duration of a detection with 5 detection cycles E takes, for example, 20 seconds for benzene (for example, 36 seconds for perchloroethylene).
On the other hand, the selectivity of the sensor 2 is dependent on the selection of the electrode material and of the electrolyte. Moreover, the maximum potential-dependent enrichment rate and also the potentialdependent oxidation current C flowing during the electrochemical reaction play a significant role, since different substances are oxidized or, in the reverse case, reduced, at different potentials. In the method presented here, several measurement parameters are available for increasing the selectivity of the measured signal. On the side of the sensor, this includes the electrode material and the electrode metal, the electrolyte, the pH value of the electrolyte solution and the material of the film on the solution side (in the case of a sensor for the liquid phase). The extent and the rate of adsorption of the substance to be detected can be influenced by ions or additives in the electrolyte, which themselves adsorb at a certain potential without being reacted. This effect depends strongly on the nature of the substance to be detected and therefore leads to a higher selectivity of the sensor. On the electronics side of the sensor, these measurement parameters include the adsorption potential, the oxidation potential (in the case of linear potential ranges, this corresponds to the potential at which the oxidation current is detected), the time at which—in the case of oxidation at constant potential—the oxidation current is detected, and the slope of the potential range (different substances are oxidized at different rates). The special advantage of the electronically alterable parameters lies in the fact that they can be altered automatically or manually very rapidly.
FIG. 5 shows a diagram of a potential-time curve for the general potential method for the detection of two substances. In the diagram, the ordinate shows the potential in volts and the abscissa the time in seconds. The detection of two substances to be detected will be explained on the example of perchloroethylene and toluene in air using a platinum-coated electrode surface and a 1M HClO 4 electrolyte solution.
In a first detection step A 1 , a low potential of 50 mV is applied to the sensor electrode 4 for 20 seconds, during which both the perchloroethylene as well as the toluene become enriched at the electrode surface.
In a second detection step B—also called potential jump B below—the potential is increased suddenly to 900 mV. The magnitude of this potential value is chosen so that oxidation of the two enriched substances still does not occur.
In a third detection step C—also called oxidation C below—the potential is increased linearly in time at a potential increase rate of 300 mV/s. During this, the two enriched substances are oxidized.
In a fourth detection step D—also called reduction D below—the potential is decreased suddenly to a low potential at which the adsorbed oxygen is reduced and any residues of toluene and perchloroethylene present are desorbed.
The three detection steps B, C and D again form a detection cycle E. This detection cycle E can be repeated five times in succession (not shown). As a result of this, the toluene and perchloroethylene are removed from the electrode surface as completely as possible.
In a fifth detection step A 2 , a low potential of 300 mV is applied to the sensor electrode 4 at which mainly only toluene is enriched. Then the potential jump B, oxidation C and reduction D are repeated, where, during oxidation C, only the enriched toluene is oxidized. Perchloroethylene would also become oxidized at the applied potential. However, due to the exclusive enrichment of toluene in the fifth detection step A 2 , this oxidation of perchloroethylene is eliminated.
Subsequent detection cycles E follow, consisting of potential jump B, oxidation C and reduction D in order to determine the oxygen adsorption on the electrode surface and the changes of the electrode surface. During the entire detection, the current-time curve is measured and recorded in order to correlate the corresponding current values with the substance concentrations. However, it is also sufficient to report only the current values during the oxidation at the maximum or at a characteristic is potential. For this purpose, first, the oxidation currents are measured that arise from the oxidation C of the first enriched layer—consisting of perchloroethylene and toluene—and from the oxidation C of the second enriched layer—consisting largely of toluene. Analogously to the detection method shown in FIGS. 4 a and 4 b , the difference values of the oxidation currents measured in the first and fifth detection cycles E are determined.
The difference value obtained in this way, which originates from the oxidation C of the second enriched layer—consisting largely of toluene—is a measure of the toluene concentration in the investigated substance mixture, since the portion of the current to be attributed to the adsorption of oxygen is eliminated from the oxidation current C′. The difference of the difference values obtained above is again a measure of the perchloroethylene concentration, since the part of the oxidation current C, attributable to oxygen adsorption as well as to oxidation of toluene is eliminated.
Thus, corresponding to the applied potential program, the sensor 2 can distinguish between different substances to be detected. This applies especially to substances to be detected in a mixture, where the enrichment potentials differ greatly—such as perchloroethylene and toluene, benzene or vinyl acetate. These can also be enriched at considerably more anodic potentials.
FIGS. 6 a-c show in diagrams a potential-time curve (FIG. 6 a ), a corresponding alternating current transient A′ (FIG. 6 b ) and a corresponding dc time curve C′ (FIG. 6 c ) for the combined detection method, that is, for the measurement of the electrode capacitance during substance enrichment and the measurement of the current during the subsequent electrochemical reaction of the substance(s) thus enriched. In the diagram of FIG. 6 a , the ordinate gives the potential in volts and the abscissa the time in seconds. In the diagrams of 6 b and 6 c , the ordinate gives the imaginary part of the alternating current and the direct current in mA, respectively, the abscissas show the time in seconds.
A low frequency alternating voltage is superimposed on the established potential value during enrichment A. As in the modified alternating current method, thus, by measuring the alternating current transients, the enrichment of the substance to be detected on the electrode surface is followed. The electrochemical reaction or oxidation C is started only when a sufficient amount of substance has been enriched on the electrode surface. The resulting oxidation current C′ thus yields a sufficiently large measured signal and thus a reliable determination of the concentration of the enriched substance. This concentration determination is related to the enrichment time in order to obtain the actual concentration of the substance to be detected in the investigated mixture.
Thus, in this method presented here, the enrichment time is no longer constant, but is adapted automatically to the existing substance concentration. A shorter enrichment time is sufficient for a higher substance concentration, while a lower substance concentration requires a longer enrichment time in order to enrich a sufficient amount of substance on the electrode surface. Furthermore, this method offers advantageously a continuous function control of the sensor by measuring the current in the fifth detection cycle and the capacitance without enrichment. | Processes and devices are disclosed for continuously detecting at least one substance in a gaseous or liquid mixture by means of a sensor electrode to which is applied a variable potential. In an alternative, the substances are concentrated at the surface of the sensor electrode, their concentration is determined by measuring the electrode capacity, the thus obtained measurement value is correlated with the substance and the substance. concentrated at the surface of the sensor electrode is then removed. In another alternative, one or several detection cycles are carried out. In each detection cycle, at least one substance is concentrated at the surface of the sensor electrode, the potential is brought to at least one potential characteristic of the electrochemical reaction of at least one substance, the resulting current is measured and the thus obtained measurement values are correlated with the substances. | 64,631 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 12/896,533 filed Oct. 1, 2010, now U.S. Pat. No. 8,516,062, issued Aug. 20, 2013, and is related to co-pending application to Killoran et al., entitled “Generation and Retrieval of Report Information,” U.S. patent application Ser. No. 12/896,644, filed Oct. 1, 2010, which are herein incorporated by reference in its entirety.
TECHNICAL FIELD
The subject matter disclosed herein relates to the storage, communication, and display of task-related data.
BACKGROUND
An organization, such as a military unit, commercial enterprise, or other type of organization, may be required to periodically perform one or more tasks in order to achieve goals and/or comply with requirements associated with their particular domain. As one example, a commercial enterprise or military unit may be required to comply with environmental regulations. Conformance to the environmental regulations may require the periodic performance of tasks such as inspecting hazardous waste accumulation areas, complete hazardous material inventories, updating or maintaining environmental records, and/or other tasks.
Current information management systems allow organizations to define tasks, assign tasks to workers, and monitor completion of the tasks that have been assigned to workers. However, these information management systems are difficult to use, unnecessarily complex, and frequently include many features that are not of interest to the user. Further, these information management systems typically include their own log in and/or authentication mechanisms, thereby adding an additional layer of complexity and inconvenience to their use. Therefore, new information management technologies are required that provide a more streamlined and straightforward user experience than what is provided in the current technologies.
SUMMARY
An information management system may store information related to tasks to be performed by workers in an organization, and may transmit information to the workers regarding tasks they are expected to perform. Further, the information management system may receive information from the workers regarding the progress of the performance of tasks, such as whether a particular task has been completed or is still in progress. The information management system may also receive requests to generate reports regarding task progress across the organization, and communicate the generated reports to workers. Communication between the workers and the information management system may be performed using email messages. The information management system may not require a login or authentication procedure that is specific to the information management system, and workers may interact with the information management system without logging in to the information management system.
The information management system may be included in an architecture that also includes one or more client modules such as an email client module and/or a report display module that are used by a worker in the organization. The information management system may generate an email message for transmission to the worker. The email message may include one or more mail to hyperlinks that describe a new email message that may be generated when the hyperlink is selected. The worker may select one of the hyperlinks, thereby generating a new email message. The new email message may include a subject field that includes an action type parameter. The action type parameter may describe an action to be performed by the information management system. The new email message may then be sent to the information management system. The information management system may then perform the action indicated by the action type parameter. The action may be, for example, updating a database to indicate that a task has been completed or is incomplete, reassigning a task from one worker to another, or generating and transmitting a report to a worker.
BRIEF DESCRIPTION OF THE DRAWINGS
A more detailed understanding may be had from the following description, given by way of example in conjunction with the accompanying drawings wherein:
FIG. 1 shows an example architecture that may be used for the communication, storage, and display of information related to task management;
FIGS. 2A-2B show a method for the communication of an alert message to a worker and for updating the task information database 116 based on a response to the alert message
FIG. 3 shows an example email display window that may be used to display an email message;
FIG. 4 shows an example message composition window that may be used to display, edit, and/or transmit an email message;
FIGS. 5A-5B show a method for updating a task information database with information related to new workers, new tasks, and/or new assignments of tasks to workers;
FIG. 6 shows an example email display window that may be used to display an email message;
FIGS. 7A-7B show a first method for the generation and transmission of a report that describe the status of task completion;
FIG. 8 shows an example email display window that may be used to display an email message;
FIG. 9 shows a first example page of a report that may be generated by an information management system;
FIG. 10 shows a second example page of a report that may be generated by an information management system;
FIG. 11 shows a second method for the generation and transmission of a report that describe the status of task completion; and
FIG. 12 shows an example system that may be used to implement the architecture of FIG. 1 .
DETAILED DESCRIPTION
FIG. 1 shows an example architecture 110 that may be used for the communication, storage, and display of information related to task management. The example architecture 110 includes an information management system 100 and a worker email client module 118 . As will be described in further detail below, the information management system 100 may store information related to tasks to be performed by workers in an organization, and may transmit information to the workers regarding tasks they are expected to perform. Further, the information management system 100 may receive information from the workers regarding the progress of the performance of tasks (e.g., whether a particular task has been completed or is still in progress). The information management system 100 may also generate reports regarding task progress across the organization, and communicate the reports to workers.
The information management system 100 may include a report module 102 , an update module 104 , an alert module 106 , a system email client module 108 , a report display module 112 , a database module 114 , and a task information database 116 . The task information database 116 may store information related to one or more tasks, one or more organizations, and one or more workers, and/or other task-related information. The database module 114 may perform functionality such as adding data to, modifying data in, querying data from, and/or retrieving data from the task information database 116 .
The alert module 106 may perform functionality such as determining when an alert message related to a task should be sent to a worker. An alert message may indicate, for example, that the worker is required to complete a task and/or what the worker is required to perform in order to complete the task.
The system email client module 108 may perform functionality such as the transmission and reception of email messages. The system email client module 108 may be configured to use one or more email accounts that are associated with the information management system 100 , and to receive messages associated with the one or more email accounts. As an example, when the alert module 106 makes a determination that an alert message should be sent to a worker, the alert module 106 may communicate the contents of the email message to the system email client module 108 , and the system email client module 108 may transmit a corresponding email message. Further, when a new email message is received at an email account used by the system email client module 108 , the system email client module 108 may communicate the email messages to the update module 104 and/or the report module 102 .
The update module 104 may perform functionality related to updating the task information database 116 based on emails from workers that are received by the system email client module 108 . For example, the update module 104 may periodically check the system email client module 108 to determine if a new email message has been received. If the update module 104 determines that an email message indicates that a task has been completed, the update module 104 (in conjunction with the database module 114 ) may update the task information database 116 accordingly.
The report module 102 may perform functionality related to providing reports to workers in the organization. For example, the report module 102 may periodically check the system email client module 108 to determine if a new email message has been received. If the report module 102 determines that a new email message has been received that indicates a request for a report from a worker, the report module 102 may generate the corresponding report, and may communicate the report to the system email client module 108 . The system email client module 108 may then transmit a corresponding email message that includes the report to the worker that requested the report. The report display module 112 may then display the report via a display device (not depicted).
The worker email client module 118 may perform functionality related to the communication and display of email messages. The worker email client module 118 may be configured to use an email account that is associated with a worker in the organization, and to receive messages associated with the email account.
The system email client module 108 and/or the worker email client module 118 may communicate email messages using technologies such as Simple Mail Transfer Protocol (SMTP), Post Office Protocol (POP) technology, Internet Message Access Protocol (IMAP), Remote Procedure Call (RPC) technology, HyperText Transfer Protocol (HTTP), and/or other appropriate technologies. The system email client module 108 and/or the worker email client module 118 may be or include an email client such as Microsoft Outlook, Thunderbird, a web browser, or any other client application for the communication of email messages. The system email client module 108 and/or worker email client module 118 may communicate email messages via one or more email servers (not depicted).
The task information database 116 may be spread across one or any number of computer-readable storage media (not depicted). The task information database 116 may be or include, for example, a relational database, a hierarchical database, an object-oriented database, a flat file, a spreadsheet, or a structured file. The database module 114 may interface with a database management system (not depicted) in order to add data to, modify data in, or obtain data from the task information database 116 . Alternatively or additionally, the database module 114 may perform database drive and/or database client functionality to interact with the database management system. The database management system may be based on a technology such as Microsoft SQL Server, Microsoft Access, MySQL, PostgreSQL, Oracle Relational Database Management System (RDBMS), or any other appropriate technology.
The task information database 116 may include data that describes tasks in terms of “recurrences.” A “recurrence” is an instance of a performance of a task. As an example, an organization may be required update its hazardous material inventories once per month. In this example, the “task” is updating hazardous material inventories, and the task is associated with a “recurrence” for each month. The task information database 116 may therefore include information that indicates that the task is associated with a recurrence each month. Further, for each task, the task information database 116 may include information such as one of or any combination of the following: an identifier of the task; a name of the task; a description of the task; an area related to the task; a date on which the task is due; an end date for the task; one or more alert dates that indicate when alert messages related to the task should be sent; files that are related to the task; an identifier of a worker to whom the task should be escalated if the task is not timely completed; recurrence information; and/or other information. Recurrence information for a task may include, for example, how often a task recurs, in which week a task recurs, on what day a task recurs, and/or other information.
For each recurrence of a task, the task information database 116 may include information such as one of or any combination of the following: an identifier of the recurrence; an identifier of the associated task; a date on which the task/recurrence must be performed; one or more dates on which alerts related to the recurrence should be sent; information that indicates whether alerts related to the recurrence have been sent; an identifier of the worker assigned to perform the task/recurrence; information that indicates when and/or if information an escalation email was sent; information related to performance of the task/recurrence; and/or other information. Information related to performance of the task/recurrence may include, for example, information that indicates that the task has been completed or is still in progress, a time at which the worker indicated that the recurrence was completed or is still in progress, an identifier of the worker who completed the recurrence, and/or comments from the worker related to progress of the performance of the recurrence. A spell-checker module (not depicted) in the information management system 100 may periodically perform spelling and grammar corrections on the comments that are included in the task information database 116 .
For each worker, the task information database 116 may include information such as one of or any combination of the following: an identifier; a first name; a last name; a position title or job description; an email address; one or more phone numbers; one or more fax numbers; an identifier of the organization with which the worker is associated; and/or other information. The information may also include privileges and/or security information, such as whether the worker is authorized as an administrator and/or what level of privileges are possessed by the worker. The task information database 116 may also include information that describes one or more email signatures associated with the worker.
For each organization in the task information database 116 , information may be stored such as: an identifier of the organization; a name of the organization; a description of the organization; and/or other information. The task information database 116 may also include information that describes facilities that are associated with an organization. For each facility in the task information database 116 , the task information database 116 may include information such as the name of the facility and the address of the facility. The task information database 116 may also include information that indicates which facility a worker is associated with.
Each or any combination of the modules 102 , 104 , 106 , 108 , 112 , 114 , 118 may be implemented as software modules, specific-purpose processor elements, or as combinations thereof. Suitable software modules include, by way of example, an executable program, a function, a method call, a procedure, a routine or sub-routine, one or more processor-executable instructions, an object, or a data structure.
Further characteristics of the modules 102 , 104 , 106 , 108 , 112 , 114 , 118 are described below with references to FIGS. 2A-12 .
FIGS. 2A-2B show a method for the communication of an alert message to a worker and for updating the task information database 116 based on a response to the alert message. As will be described in further detail below, the alert message may indicate that a task recurrence is expected to be performed by the worker. FIGS. 2A-2B show the database module 114 , the update module 104 , the alert module 106 , the system email client module 108 , and the worker email client module 118 .
The method of FIGS. 2A-2B may begin with the alert module 106 determining that an alert related to a task recurrence should be sent (step 232 ). This determination may be performed based on data obtained via the database module 114 from the task information database 116 . As one example, the alert module 106 may receive information from the task information database 116 that indicates that, for a particular task recurrence, an alert email is past due and has not been sent.
The alert module 106 and/or the system email client module 108 may then generate an email message to be transmitted to the worker assigned to perform the recurrence of the task (step 234 ). The email message may describe the task recurrence to be performed. The email message may also include one or more attachments that provide information regarding the task recurrence to be performed. The email message may be indicate that it is being sent by one of the email accounts used by the system email client module 108 . Further, the email message may include one or more hyperlinks that, when clicked by the worker, will create a new email message that the worker may use to respond to the email message generated by the alert module 106 and/or system email client module 108 .
The system email client module 108 may then transmit the generated email message (step 236 ). The email message may be received by the worker email client module 118 , and displayed by the worker email client module 118 (step 238 ).
Referring now to both FIG. 2A and FIG. 3 , FIG. 3 shows an example email display window 320 that may be used by the worker email client module 118 to display the email message (step 238 ). The email display window 320 of FIG. 3 includes a Reply button 322 , a control area 324 , and a message body area 326 . The control area 324 may display control and/or header information associated with the email message, such as the email addresses of the sender and recipient of the message. As an example, the control area 324 shows that the sender of the message has the email address “[email protected].” This is an example email address that may be associated with an account used by the information management system 100 for the communication of email messages. Further to this example, the control area 324 shows that the email address of the worker assigned to perform the task recurrence is “[email protected].” The control area 324 may also display information such as a subject of the email message and the time the email message was sent. The control area 324 may also display information that indicates whether any attachments are associated with the email message. The Reply button 322 may respond to user input to generate a new display element (not depicted) to respond to the email message.
The message body area 326 may display the body of the email message. As shown in FIG. 3 , the message body area 326 display an example email message that describes a task recurrence to be performed by an example worker named John Smith.
The message body area 326 may also include one or more Uniform Resource Identifiers (URIs) or hyperlinks, such as the “Completed Task” link, the “Incomplete Task” link, the “Comments” link, and/or the “Redirect Task” link. These links may be defined according to the mail to URI scheme or other appropriate format, and each may describe a new email message that may be generated by the worker email client module 118 when that link is selected. A mail to URI scheme may include one or any combination of the following fields: a “mail to:” and/or “to” field that indicate one or more email addresses of recipients of the new message; a “Copy To” or “CC” field that indicates one or more email addresses of recipients to whom a copy of the new message should be sent; a “Blind Copy To” or “BCC” field that indicates one or more email addresses of recipients to whom a blind copy of the new message should be sent; a field that indicates the subject of the new message; and a field that indicates the body of the new message. A mail to hyperlink may be defined according to the format described in Internet Engineering Task Force (IETF) RFC2368.
Each of the hyperlinks may specify that the subject field in the new email message includes an action type parameter that indicates a type of an action to be performed by the information management system 100 . Types of actions that the information management system 100 may perform include updating the task information database 116 to indicate that a task has been completed or is incomplete, updating the task information database 116 with a comment related to a task, reassigning a task from the currently-assigned worker to a new worker, and/or other actions. Further, each of the hyperlinks may specify that the subject field in the new email message includes an identifier of the task recurrence that is described in the message body area 326 . Further, each of the hyperlinks may specify that the new email message should be addressed to an email account used by the information management system 100 .
The “Completed Task” hyperlink may include information that describes an email message that, if received by the information management system 100 , will indicate to the information management system 100 that a task recurrence has successfully been completed, and that the task information database 116 should be updated accordingly. As an example, the task recurrence described in the message body area 326 may have an identifier of “ID001,” and an action type parameter that indicates that the task information database 116 should be updated to reflect completion of a task may be “COMPLETED$.” Further to this example, the Completed Task hyperlink may describe a new email message with a subject that includes the text “Response Task ID001 COMPLETED$.”
The “Incomplete Task” hyperlink may include information that describes an email message that, if received by the information management system 100 , will indicate to the information management system 100 that a task recurrence is incomplete. As an example, the task recurrence described in the message body area 326 may have an identifier of “ID001,” and an action type parameter that indicates that the task information database 116 should be updated to reflect that the task is incomplete may be “INCOMPLETE$.” Further to this example, the Incomplete Task hyperlink may describe a new email message with a subject that includes the text “Response Task ID001 INCOMPLETE$.”
The “Comments” hyperlink may include information that describes an email message that, if received by the information management system 100 , will indicate to the information management system 100 that the worker is providing a comment on a task recurrence. As an example, the task recurrence described in the message body area 326 may have an identifier of “ID001,” and an action type parameter that indicates that the task information database 116 should be updated to include the comments may be “INPROGRESS$.” Further to this example, the Incomplete Task hyperlink may describe a new email message with a subject that includes the text “Response Task ID001 INPROGRESS$.” As will be described in further detail below, by using a “Comments” email message, a worker may provide comments to the information management system 100 . Comments may include information such as whether the worker needs additional support to complete a task recurrence, whether the worker is concerned about their progress with respect to a task recurrence, and/or any other information provided by the worker.
The “Redirect Task” link may include information that describes an email message that, if received by the information management system 100 , will indicate to the information management system 100 that the worker is requesting that the task or task recurrence mentioned in the message body area 326 be reassigned to a different worker. As an example, the task recurrence described in the message body area 326 may have an identifier of “ID001,” and an action type parameter that indicates that the task information database 116 should be updated to reassign a task may be “REDIRECT$.” Further to this example, the Redirect Task hyperlink may describe a new email message with a subject that includes the text “Response Task ID001 REDIRECT$.” The Redirect Task hyperlink may also specify that the body of the new message begins with the text “New Assigned User Email Address:” As will be described in further detail below, a worker may add the email address of a worker to the body of the email message generated based on the Redirect Task hyperlink, and thereby reassign a particular task or task recurrence to a different worker.
The worker email client module 118 may receive a user input that indicates that one of the hyperlinks displayed in the message body area 326 is selected. The user input may be, for example, a mouse click, keyboard input, or any other type of input that indicates that a hyperlink is selected. Referring again to FIG. 2A , the worker email client module 118 may, in response to this user input, generate a response message as specified by the selected hyperlink (step 240 ). Generation of the response message may include displaying the generated response message in one or more user interface elements.
Referring now to FIG. 2A , FIG. 3 , and FIG. 4 , FIG. 4 shows an example message composition window 420 that may be displayed in response to a selection hyperlink from the message body area 326 of FIG. 3 (step 240 ). The message composition window 420 of FIG. 4 may include a Send button 422 , a To area 421 , a CC area 423 , a BCC area 425 , a Subject area 427 , and a message body area 426 . The Send button 422 in the message composition window 420 of FIG. 4 may be responsive to input from a user such as a mouse click, keyboard input, or any other type of input. The different areas 421 , 423 , 425 , 426 , 427 in the message composition window 420 display different portions of an email message. For example, the To area 421 includes text that indicates email addresses to which the email message is addressed, while the message body area 426 displays the contents of the body of the email message. Each or any of these different areas 421 , 423 , 425 , 426 , 427 may be editable based on user input. Changes to the contents of these areas 421 , 423 , 425 , 427 , 426 may be change the corresponding portion of the email message.
FIG. 4 shows an example wherein the Completed Task hyperlink from the message body area 326 of FIG. 3 is selected. The To area 421 indicates that the message is addressed to [email protected]. The Subject area 427 indicates that the subject of the message is “Response Task ID001 COMPLETED$.” The CC area 423 , BCC area 425 , and message body area 426 are blank. In an instance where a different hyperlink from the message body area 326 of FIG. 3 (e.g., the Incomplete Task hyperlink, Comments hyperlink, or Redirect Task hyperlink) is selected, the display areas 421 , 423 , 425 , 427 , 426 in the message composition window 420 may include contents specified by the selected different hyperlink.
A user may add text to the body of the email message by adding text to or changing the text in the message body area 426 . As will be described in further detail below, the information management system 100 may interpret the text in the message body of an email message in different ways, based on information indicated in the subject of the email message and/or the purpose of the email message. For example, the body of the email message may be interpreted by the information management system 100 as a comment related to the completion of a task recurrence, or the information management system 100 may expect the body of the email message to include an email address of the new user to whom a task or task recurrence is being reassigned.
Referring now to both FIG. 2B and FIG. 4 , the worker email client module 118 may, in response to a selection of the Send button 422 , transmit the email message based on the contents of the 421 , 423 , 425 , 426 , 427 in the message composition window 420 (step 242 ).
The system email client module 108 and the update module 104 may then receive the email message (step 244 ). This may include, for example, the update module 104 periodically querying the system email client module 108 for information related to new messages received by the system email client module 108 for one or more of the email accounts used by the information management system 100 . Referring again to the example described above with reference to FIG. 4 , the email message may be addressed to [email protected]. Further to this example, the update module 104 may periodically obtain new messages from the system email client module 108 that have been received for the [email protected] email account.
The update module 104 (in conjunction with the database module 114 ) may then verify the contents of the received message and update the task information database 116 accordingly (step 246 ). This may include, for example, the update module 104 parsing the contents of the received email message to determine if the message is formatted appropriately. For example, the update module 104 may be configured to expect that a received email message may include certain contents in its subject field, related to the type and/or purpose of the message. The update module 104 may determine whether the subject field of the message contains expected text such as “COMPLETED$,” “INCOMPLETE$,” “INPROGRESS$,” or “REDIRECT$.” The update module 104 may also determine whether the email address indicated as the sender of the message corresponds to the worker assigned to the corresponding task, and/or whether a task identifier of task recurrence identifier included in the subject of the message is valid.
Alternatively or additionally, if the received message is a message for redirecting a task or task recurrence to a new worker, the update module 104 may verify that reassignment of the task or task recurrence is permitted. This may include, for example, determining whether information about the new worker is included in the task information database 116 , whether the new worker is associated with the organization with which the task or task recurrence is associated, and/or whether the worker attempting to reassign the task or task recurrence is an administrator and/or has appropriate privileges to reassign the task.
If the update module 104 successfully verifies the contents of the response message, the update module 104 may communicate with the database module 114 to update the task information database 116 accordingly. For example, if the received message indicates that a task recurrence has been completed or is incomplete, the task information database 116 will be updated to reflect the complete/incomplete status of the task recurrence. If the task recurrence is complete, this may also include the task information database 116 being updated to indicate that the worker who transmitted the response message completed the task. Further, the task information database 116 may be updated to indicate that the task was completed as of the time that the response email was received. Additionally, the update module 104 may add the text in the body of the email message to the task information database 116 as a comment on the task recurrence. Alternatively, if the received message is a comments message (i.e., the subject of the email includes “INPROGRESS$”), the update module 104 will add the text in the body of the email message to the task information database as a comment on the task recurrence. Alternatively, if the received message is a reassignment message, the update module 104 will update the task information database 116 to reflect that the task or task recurrence has been reassigned to the new worker.
As described above, the update module 104 may add a comment related to a task recurrence to the task information database 116 that is based on the contents of the received email message body. When doing so, the update module 104 may determine whether the email message body contains an email signature for the worker that transmitted the email message. This may be performed by, for example, comparing the text in the email message body to an email signature for associated with the worker that is stored in the task information database 116 . If the message body contains an email signature, the update module 104 may remove the signature from the message body before adding the message body as a comment into the task information database 116 .
The update module 104 and/or the system email client module 108 may then generate a result message that indicates the results of the message verification and database update (step 248 ). This may include the update module 104 generating the contents of the result message, and communicating the contents to the system email client module 108 . If the update module 104 determined that the response message could not be verified, the update module 104 may generate contents for an email message that indicate the reason why the response message could not be verified. For example, the contents may indicate that the task recurrence identifier in the response message was invalid, or that the response message was invalid for any of the other reasons described above. Alternatively, if the update module 104 and the database module 114 successfully updated the task information database 116 based on the response message, the update module 104 may generate contents for an email message that indicate that the update was successful. The generated result message may be addressed to indicate that it is being sent by one of the email accounts used by the system email client module 108 .
The system email client module 108 may then transmit the generated result email message to the worker email client module 118 (step 250 ).
FIGS. 5A-5B show a method for updating the task information database with information related to new workers, new tasks, and/or new assignments of tasks to workers. FIGS. 5A-5B shows the database module 114 , the update module 104 , the system email client module 108 , and the worker email client module 118 .
The method of FIGS. 5A-5B may begin with the update module 104 and/or the system email client module 108 generating an administrative email message for transmission to the worker email client module 118 (step 530 ). The administrative email message may indicate that it is being sent by one of the email accounts used by the system email client module 108 . The administrative email message may include one or more mail to hyperlinks that the worker email client module 118 may use to create a new email message. The hyperlinks may, for example, specify email messages for performing one or more administrative tasks in the information management system 100 such as adding a new user to the task information database 116 , adding a new task to the task information database 116 , and/or reassigning tasks in the task information database 116 to different users.
The system email client module 108 may then transmit the generated administrative email message to the worker email client module 118 (step 532 ). After receiving the administrative email message, the worker email client module 118 may display the received administrative email message (step 534 ).
Referring now to both FIG. 5A and FIG. 6 , FIG. 6 shows an example email display window 620 that may be used by the worker email client module 118 to display the received administrative message (step 534 ). The email display window 620 of FIG. 6 includes a Reply button 622 , a control area 624 , and a message body area 626 . The control area 624 may display control and/or header information associated with the administrative email message, such as the email addresses of the sender and recipient of the message. The Reply button 622 may respond to user input to generate a new display element (not depicted) to respond to the administrative email message.
The message body area 626 in the email display window 620 may display the body of the administrative email message. As an example, the message body area 626 may include one or more URIs or hyperlinks, such as the “Add New User” link, the “Add New Task” link, and/or the “Reassign Task(s)” link. These links may be defined according to the mail to URI scheme or other appropriate format, and each may describe a new email message that may be generated by the worker email client module 118 when that link is selected. Each of the hyperlinks may specify that the subject field in the new email message includes an indicator of the purpose of the hyperlink. For example, the “Add New User” hyperlink may include the action type parameter “NEWUSER$” to indicate that the message relates to the addition of a new worker to the task information database 116 . Further, each of the hyperlinks may specify that the subject field in the new email message includes an identifier of the client with which the subject matter of the new email is associated. Additionally, each of the hyperlinks may specify that the new email message should be addressed to an email account used by the information management system 100 .
The Add New User hyperlink may include information that describes an email message that may be used to add information for a new user to the task information database 116 . As an example, the worker email client module 118 may be used by a worker that is associated with an organization that has an identifier of “ORG001,” and an action type parameter that indicates that the task information database 116 should be updated to add a new user may be “NEWUSER$.” Further to this example, the Add New User hyperlink may describe a new email message with a subject that includes the text “Response Client ID001 NEWUSER$.” The Add New User hyperlink may also describe that the body of the new email message should include the following text:
“First Name:
Last Name:
Position:
Email:
Phone 1:
Phone 2:
Fax:”
The Add New Task hyperlink may include information that describes an email message that may be used to add a new task to the task information database 116 . As an example, the worker email client module 118 may be used by a worker that is associated with an organization that has an identifier of “ORG001,” and an action type parameter that indicates that the task information database 116 should be updated to add a new task may be “TASK$.” Further to this example, the Add New Task hyperlink may describe a new email message with a subject that includes the text “Response Client ID001 TASK$.” The Add New User hyperlink may also describe that the body of the new email message should include the following text:
“Task Name:
Task Due Date:
Alert Date One:
Alert Date Two:
Alert Date Three:
Assigned User Email Address:”
The Reassign Task(s) hyperlink may include information that describes an email message that may be used to reassign one or more tasks from one worker to another worker. As an example, the worker email client module 118 may be used by a worker that is associated with an organization that has an identifier of “ORG001,” and an action type parameter that indicates that the task information database 116 should be updated to reassign tasks may be “ASSIGN$.” Further to this example, the Reassign Task(s) hyperlink may describe a new email message with a subject that includes the text “Response Client ID001 ASSIGN$.” The Reassign Task(s) hyperlink may also describe that the body of the new email message should include the following text:
“Task Name:
Older User Email:
New User Email:”
The worker email client module 118 may receive a user input that indicates that one of the hyperlinks displayed in the message body area 626 of the email display window 620 is selected. The user input may be, for example, a mouse click, keyboard input, or any other type of input that indicates that a hyperlink is selected. Referring again to FIG. 5A , the worker email client module 118 may, in response to this user input, generate an administrative update message as specified by the selected hyperlink (step 536 ). The worker email client module 118 may display the generated administrative update message via a display device (not depicted) in a message composition window (not depicted) with similar characteristics to the message composition window 420 of FIG. 4 . A user may modify the generated administrative update message using the message composition window 420 . This may include adding text to the body of the administrative update message and/or changing the text of the body of the administrative update message. For example, to specify a new user to be added to the task information database 116 , the user may add additional text to the body of the administrative update message related to the new user, such as a first name, last name, position, email address, one or more phone numbers, and/or a fax number. As an example, the user may modify the body of the administrative update message to add a new user named “James Smith,” such that body of the administrative update message includes the following text:
“First Name: James
Last Name: Smith
Position: Worker
Email: [email protected]
Phone 1: 100-100-1000
Phone 2: 100-100-1001
Fax: 100-100-1002.”
To specify a new task that should be added to the task information database 116 , the user may add additional text to the body of the administrative update message such as a task name, task due date, alert dates, and/or an email address of the assigned worker. To specify the reassignment of a task, the user may add additional text to the body of the administrative update message, such as a task name, the email address of the currently assigned user, and the email address of the user to whom the task should be reassigned.
The worker email client module 118 may then transmit the administrative update message to the system email client module 108 (step 538 ).
Referring now to FIG. 5B , the system email client module 108 and the update module 104 may then receive the administrative update email message (step 540 ). This may include, for example, the update module 104 periodically querying the system email client module 108 for information related to new messages received by the system email client module 108 for one or more of the email accounts used by the information management system 100 .
The update module 104 (in conjunction with the database module 114 ) may then verify the contents of the received administrative update message and update the task information database 116 accordingly (step 542 ). This may include, for example, the update module 104 parsing the contents of the received administrative update email message to determine if the message is formatted appropriately. For example, the update module 104 may be configured to expect that a received email message may include certain contents in its subject field, related to the type and/or purpose of the message. For example, the update module 104 may determine whether the subject field of the message contains expected text such as “NEWUSER$,” “TASK$,” or “ASSIGN$.” The update module 104 may also determine whether the message body contains expected text related to the type and/or purpose of the message. If the subject of the message contains “NEWUSER$,” the update module 104 may parse the body of the message to determine whether it includes information related to a new user such as a first name, last name, position, email address, one or more phone numbers, and/or a fax number. If the subject of the message contains the text “TASK$,” the update module 104 may parse the body of the message to determine whether it includes information related to a new task such as the task name, a task due date, alert dates, and/or an email address of a worker assigned to the task. If the subject of the message contains “ASSIGN$,” the update module 104 may parse the body of the message to determine whether it includes information related to a reassignment of a task, such as a task name, the email address of the currently assigned user, and the email address of the user to whom the task should be reassigned.
The update module 104 may also determine whether the worker who transmitted the administrative update message is associated with the client identified in the subject of the message. Further, the update module 104 may determine whether the worker who transmitted the administrative update message is an administrative user and/or has the privileges required to perform the requested update. Alternatively or additionally, if the received administrative update message is a message for redirecting one or more tasks to a new worker, the update module 104 may verify that reassignment of the task is permitted. This may include, for example, determining whether information about the new worker is included in the task information database 116 , and/or whether the new worker is associated with the organization with which the tasks are associated.
If the update module 104 successfully verifies the contents of the administrative update message, the update module 104 may communicate with the database module 114 to update the task information database 116 as specified in the administrative update message. In an instance where the administrative update message related to the reassignment of a task (i.e., if the subject of the message contains “ASSIGN$,”), a special identifier for task name may be used to reassign all of the tasks currently associated with a user to a new user. As an example, if the message includes the text “ALL” as an indicator of the task name, the update module 104 will update the task information database 116 to reflect that all of the tasks associated with the currently-assigned worker are being reassigned to the new worker.
The update module 104 and/or the system email client module 108 may then generate a result message that indicates the results of the message verification and database update (step 544 ). This may include the update module 104 generating the contents of the result message, and communicating the contents to the system email client module 108 . If the update module 104 determined that the administrative update message could not be verified, the update module 104 may generate contents for an email message that indicate the reason why the administrative update message could not be verified. Alternatively, if the update module 104 and the database module 114 successfully updated the task information database 116 based on the administrative update message, the update module 104 may generate contents for an email message that indicate that the update was successful. The generated result message may be addressed to indicate that it is being sent by one of the email accounts used by the system email client module 108 .
The system email client module 108 may then transmit the generated result email message to the worker email client module 118 (step 546 ).
FIGS. 7A-7B show a first method for the generation and transmission of a report that describe the status of task completion. FIGS. 7A-7B shows the database module 114 , the report module 102 , the system email client module 108 , the report display module 112 , and the worker email client module 118 .
The method of FIGS. 7A-7B may begin with the report module 102 and/or the system email client module 108 generating report link email message for transmission to the worker email client module 118 (step 730 ). The report link email message may indicate that it is being sent by one of the email accounts used by the system email client module 108 . The report link email message may include one or more mail to hyperlinks that the worker email client module 118 may use to create a new email message. The contents of the hyperlinks may be generated by the report module 102 to include information that is specific to the worker to which the email message is addressed. For example, a hyperlink may specify a request for a report related to tasks that are associated with the organization with which the worker is associated.
The system email client module 108 may then transmit the generated report link email message to the worker email client module 118 (step 730 ). After receiving the report link email message, the worker email client module 118 may display the received report link email message (step 732 ).
Referring now to both FIG. 7A and FIG. 8 , FIG. 8 shows an example email display window 820 that may be used by the worker email client module 118 to display the received report link message (step 734 ). The email display window 820 of FIG. 8 includes a Reply button 822 , a control area 824 , and a message body area 826 . The control area 824 may display control and/or header information associated with the report link email message, such as the email addresses of the sender and recipient of the message. The Reply button 822 may respond to user input to generate a new display element (not depicted) to respond to the report link email message.
The message body area 826 in the email display window 820 may display the body of the report link email message. As an example, the message body area 826 may include one or more URIs or hyperlinks, such as the “Report One” link, the “Report Two” link, and/or the “Report Three” link. These links may be defined according to the mail to URI scheme or other appropriate format, and each may describe a new email message that may be generated by the worker email client module 118 when that link is selected. Each of the hyperlinks may specify that the subject field in the new email message includes an indicator of the purpose of the hyperlink. For example, the “Report One” hyperlink may include the action type parameter “REPORT$” to indicate that the message indicates a request for the information management system 100 to generate and transmit a report. Further, each of the hyperlinks may specify that the subject field in the new email message includes an identifier of the client with which the subject matter of the new email is associated. Additionally, each of the hyperlinks may specify that the new email message should be addressed to an email account used by the information management system 100 .
The Report One hyperlink may include information that describes an email message that may be used to request a report. As an example, the worker email client module 118 may be used by a worker that is associated with an organization that has an identifier of “ORG001.” Further to this example, the Report One hyperlink may describe a new email message with a subject that includes the text “Response Client ID001 REPORT$.” The Report One hyperlink may also specify that the new email message should include text in the body of the message that describes the report being requested. As an example, the Report One hyperlink may indicate that the body of the message includes the text “TaskSummaryReport.” The body of the message may indicate what type of report is being requested, and/or may indicate parameters (e.g., a time range, a particular task or group of tasks, a particular worker or group of workers) on which the requested report should be focused.
The Report Two and Report Three hyperlinks may specify email messages that are similar to the message specified by the Report One hyperlink, though they may specify different parameters for the bodies of their respective messages. As an example, the Report Two hyperlink may specify a report for tasks that have been performed for a first time period (such as the past month), while the Report Three hyperlink may specify a report for tasks that have been performed for a second time period (such as the past six months).
The worker email client module 118 may receive a user input that indicates that one of the hyperlinks displayed in the message body area 826 of the email display window 820 is selected. The user input may be, for example, a mouse click, keyboard input, or any other type of input that indicates that a hyperlink is selected. Referring again to FIG. 7A , the worker email client module 118 may, in response to this user input, generate a report request email message as specified by the selected hyperlink (step 736 ). The worker email client module 118 may display the generated report request message via a display device (not depicted) in a message composition window (not depicted) with similar characteristics to the message composition window 420 of FIG. 4 . A user may modify the generated report request message using the message composition window. This may include adding text to the body of the report request message and/or changing the text of the body of the report request message.
The worker email client module 118 may then transmit the report request message to the system email client module 108 (step 738 ).
Referring now to FIG. 7B , the system email client module 108 and the report module 102 may then receive the report request message (step 740 ). This may include, for example, the report module 102 periodically querying the system email client module 108 for information related to new messages received by the system email client module 108 for one or more of the email accounts used by the information management system 100 .
The report module 102 (in conjunction with the database module 114 ) may then verify the contents of the received report request message and, if the received report request is acceptable, generate the requested report (step 742 ). Verifying the report request may include the report module 102 determining whether the worker who transmitted the report request message is associated with the client identified in the subject of the message. Further, the report module 102 may determine whether the worker who transmitted the report request message is an administrative user and/or has the privileges required to receive the requested report.
Verifying the report request message may also include the report module 102 determining whether the message is formatted correctly. For example, the report module 102 may be configured to determine whether the subject field of the message contains text such as “REPORT$,” and/or whether the body of the email includes appropriate parameters for defining the scope of a report.
If the report module 102 successfully verifies the contents of the report request message, the report module 102 may obtain data from the task information database 116 (via the database module 114 ) and generate a report as specified in the report request message. The report may be one or more electronic files. The one or more electronic files may be defined according to formats such as but not limited to Portable Document Format (PDF), Tagged Image File Format (TIFF), and/or any other appropriate format.
The report module 102 and/or the system email client module 108 may then generate a report email message for transmission to the worker email client module 118 (step 744 ). This may include the report module 102 communicating the contents of the report message to the system email client module 108 . The generated report message may be addressed to indicate that it is being sent by one of the email accounts used by the system email client module 108 , and the generated report message may include the one or more report documents as attachments. The system email client module 108 may then transmit the report email message to the worker email client module 118 (step 746 ). The report display module 112 may then display the report (step 748 ) on a display device (not depicted).
Referring now to both FIG. 7B and FIG. 9 , FIG. 9 shows a first example page 920 of a report that may be displayed by the report display module 112 (step 748 ). The first example page 920 shows report data that relates to tasks assigned to workers in an organization with ID “ORG001” for a given month. ORG001, according to this example, has two facilities, named “Facility One” and “Facility Two.” The first example page 920 includes a report area 922 , which includes a bar graph 924 . The bar graph 924 includes a Facility Two complete area 930 , which indicates the total number of task recurrences that have been completed at Facility Two in the month. The bar graph 924 also includes a Facility One complete area 926 and a Facility One incomplete area 928 , which indicate the total number of task recurrences that have been completed and which still remain incomplete, respectively, at Facility One.
Referring now to both FIG. 7B and FIG. 10 , FIG. 10 shows a second example page 1020 of a report that may be displayed by the report display module 112 (step 748 ). The second example page 1020 continues with the example from the first example page 920 of FIG. 9 , and shows data related to the completion of tasks at Facility One. The second example page 1020 includes a pie chart 1028 that indicates the percentage of completed versus incomplete task recurrences for the month. The second example page 1020 also includes a first worker-specific task area 1022 , which indicates the status of tasks that are assigned to a first user (John Smith) and are expected to be completed within the month. The second example page 1020 also includes a second worker-specific task area 1024 , which indicates the status of tasks that are assigned to a second user (Jane smith) and are expected to be completed within the month. As an alternative to the organization of tasks shown in the worker-specific task areas 1022 , 1024 , tasks may be organized in the worker-specific task areas 1022 , 1024 according to recurrence intervals. For example, information related to non-recurring tasks may be included above tasks which recur on a weekly basis, which may be included above tasks which recur on a monthly basis, and so on.
The example pages 920 , 1020 described above with reference to FIG. 9 and FIG. 10 are provided by way of example. Alternatively or additionally, the reports generated by the report module 102 may include any combination of information described above as stored in the task information database 116 .
FIG. 11 shows a second method for the generation and transmission of a report that describe the status of task completion. FIG. 11 shows the database module 114 , the report module 102 , the system email client module 108 , the report display module 112 , and the worker email client module 118 .
The method of FIG. 11 may begin with the worker email client module 118 transmitting a report request email message to the system email client module 108 (step 1130 ). The system email client module 108 and the report module 102 may then receive the report request message (step 1132 ). This may include, for example, the report module 102 periodically querying the system email client module 108 for information related to new messages received by the system email client module 108 for one or more of the email accounts used by the information management system 100 .
The report module 102 (in conjunction with the database module 114 ) may then verify the contents of the received report request message and, if the received report request is acceptable, generate a report (step 1134 ). Verifying the report request may include the report module 102 determining whether the address from which the report request email was sent is a valid email address, as stored in the task information database 116 . The report module 102 may also determine, based on the email address, whether the worker associated with the email address is an administrative user and/or has the privileges required to receive a report.
If the report module 102 successfully verifies the contents of the report request message, the report module 102 may obtain data from the task information database 116 (via the database module 114 ) and generate a report. Based on the email address from which the request message was sent, the report module 102 may determine which organization the worker is associated with, and may generate a default report that is configured for the worker's organization. The default report may include information for all of or some subset of the facilities associated with the organization, and/or the default report may be focused on some subset of workers associated with the organization, and/or the default report may be focused on a configured time period such as the current month, last six months, or other time period. Alternatively or additionally, the report module 102 may be configured to generate a different default for different workers within an organization. The report module 102 may, for example, determine which worker requested the report based on the email address from which the report request was sent, and generate a default report that is configured as a default report for that specific worker. The generated report may be one or more electronic files, and may possess any characteristic or combination of characteristics of the reports described above as generated by the report module 102 with respect to FIGS. 7A-7B , FIG. 8 , FIG. 9 , and/or FIG. 10 .
The report module 102 and/or the system email client module 108 may then generate a report email message for transmission to the worker email client module 118 (step 1136 ). This may include the report module 102 communicating the contents of the report message to the system email client module 108 . The generated report message may be addressed to indicate that it is being sent by one of the email accounts used by the system email client module 108 , and the generated report message may include the one or more report documents as attachments. The system email client module 108 may then transmit the report email message to the worker email client module 118 (step 1138 ). The report display module 112 may then display the report (step 1140 ) on a display device (not depicted). The report display module 112 may display the report in fashion identical or similar to the display of the report described above with reference to FIG. 9 and FIG. 10 .
FIG. 12 shows an example system 1200 that may be used to implement the architecture 120 of FIG. 1 . The example system 120 includes an administrative server 1250 , a database server 1260 , a client device 1270 , and one or more networks 1280 .
The administrative server 1250 may include a processor 1252 , memory device 1254 , communication interface 1256 , input device interface 1255 , display device interface 1257 , and storage device 1259 . The database server 1260 may include a processor 1262 , memory device 1264 , communication interface 1266 , input device interface 1265 , display device interface 1267 , and storage device 1269 . The client device 1270 may include a processor 1272 , memory device 1274 , communication interface 1276 , input device interface 1275 , display device interface 1277 , and storage device 1279 .
The administrative server 1250 may be configured to perform any feature or combination of features described above with reference to FIGS. 1-11 as performed by the report module 102 , update module 104 , alert module 106 , system email client module 108 , and/or database module 124 . The storage device 1269 in the database server 1260 may store the task information database 116 or a portion thereof. The database server 1260 may be configured to perform any feature or combination of features described above with reference to FIGS. 1-10 related to the storage of data in the task information database 116 . The client device 1270 may be configured to perform any feature or combination of features described above with reference to FIGS. 1-11 as performed by the worker email client module 128 and/or the report display module 122 . The client device 1270 may be, for example, a desktop computer, a laptop computer, a netbook, a tablet computer, a personal digital assistant (PDA), a cellular phone, or any other appropriate device.
Each or any of the memory devices 1254 , 1264 , 1274 may be or include a device such as a Dynamic Random Access Memory (D-RAM), Static RAM (S-RAM), or other RAM or a flash memory. Each or any of the storage devices 1259 , 1269 , 1279 may be or include a hard disk, a magneto-optical medium, an optical medium such as a CD-ROM, a digital versatile disk (DVDs), or Blu-Ray disc (BD), or other type of device for electronic data storage.
Each or any of the communication interfaces 1256 , 1266 , 1276 may be, for example, a communications port, a wired transceiver, or a wireless transceiver. Each or any of the network interfaces 1256 , 1266 , 1276 may be capable of communicating using technologies such as Ethernet, fiber optics, microwave, xDSL (Digital Subscriber Line), Wireless Local Area Network (WLAN) technology, wireless cellular technology, and/or any other appropriate technology. The communication interfaces 156 , 166 , 1276 may be used by the administrative server 1250 , database server 160 , and/or client device 1270 to communicate via the one or more networks 1280 . The communication interfaces 156 , 166 , 1276 may be used by the administrative server 1250 , database server 160 , and/or client device 1270 to communicate any message or combination of messages described above with reference to FIGS. 1-11 as communicated by the system email client module 108 , worker email client module 118 , and/or database module 114 . The one or more networks 1280 may include one or more private networks and/or one or more public networks such as the Internet. The one or more networks 1280 may be based on wired and/or wireless networking technologies.
Each or any of the input device interfaces 1255 , 1265 , 1275 may an interface configured to receive input from an input device such as a keyboard, a mouse, a trackball, a scanner, a touch screen, a touch pad, a stylus pad, and/or other device. Each or any of the input device interfaces 1255 , 1265 , 1275 may operate using a technology such as Universal Serial Bus (USB), PS/2, Bluetooth, infrared, and/or other appropriate technology.
Each or any of the display device interfaces 1257 , 1267 , 1277 may be an interface configured to communicate data to a display device. Each or any of the display device interfaces 1257 , 1267 , 1277 may operate using technology such as Video Graphics Array (VGA), Super VGA (S-VGA), Digital Visual Interface (DVI), High-Definition Multimedia Interface (HDMI), or other appropriate technology.
The memory 1254 of the administrative computer 1250 may store instructions which, when executed by the processor 1252 , cause the processor 1252 to perform any feature or combination of features described above with reference to FIGS. 1-11 as performed by the report module 102 , update module 104 , alert module 106 , system email client module 108 , and/or database module 124 . The memory 1264 of the database server 1260 may store instructions which, when executed by the processor 1262 , cause the processor 1262 to perform any feature or combination of features described above with reference to FIGS. 1-11 as related to the storage of data in the task information database 116 . These features may include, for example, executing instructions related to a database management system, storing and/or modifying data in the task information database 116 , and/or obtaining data from the task information database 116 . The memory 1274 of the client device 1270 may store instructions which, when executed by the processor 1272 , cause the processor 1272 to perform any feature or combination of features described above with reference to FIGS. 1-11 as performed by the worker email client module 128 and/or the report display module 122 .
The client device 1270 may include or be connected to a display device (not depicted) via the display device interface 1277 . The display device may be, for example, a monitor or television display, a plasma display, a liquid crystal display (LCD), and/or a display based on a technology such as front or rear projection, light emitting diodes (LEDs), organic light-emitting diodes (OLEDs), or Digital Light Processing (DLP). The display device may be configured to display, based on data received from the input device interface 1275 , any graphical elements described above with reference to FIGS. 1-11 as displayed by the worker email client module 128 and/or the report display module 122 .
As described above with reference to FIGS. 1-12 , the information management system 100 may be configured to use one or more email accounts that are associated with the information management system 100 for the transmission and reception of email communications. In various configurations, different email addresses may be used by the information management system 100 for different purposes. For example, the update module 104 may be configured to use a first email address for the transmission/reception of messages, while the report module 104 may be configured to use a second email address for the transmission/reception of messages. Alternatively, the report module 102 and/or update module 104 may be configured to use a first email address to transmit/receive email messages for performance of the methods of FIGS. 2A-2B , FIGS. 5A-5B , and FIGS. 7A-7B , while the report module 102 may be configured to use a second email address to transmit/receive email messages for performance of the method of FIG. 11 . Alternatively or additionally, the report module 102 , update module 104 , and/or alert module 106 may be configured to use different email addresses for communicating email messages to different organizations.
While examples are provided above with respect to FIGS. 1-12 which includes the use of email communications, the functionality of the information management system 100 and/or the worker email client module 126 may also be implemented using different types of communications technology. For example, the features described above with reference to FIGS. 1-12 may also be implemented, mutatis mutandis, using technologies that include any one or any combination of: email; instant messaging; enterprise messaging; Short Message Service (SMS); Multimedia Messaging Service (MMS); and/or any other appropriate technology for the electronic communication of data.
When referred to herein, the term “computer-readable storage medium” broadly refers to and is not limited to a register, a cache memory, a ROM, a semiconductor memory device (such as a D-RAM, S-RAM, or other RAM), a magnetic medium such as a flash memory, a hard disk, a magneto-optical medium, an optical medium such as a CD-ROM, a DVDs, or BD, or other type of device for electronic data storage.
Although features and elements are described above in particular combinations, each feature or element can be used alone or in any combination with the other features and elements. For example, each feature or element as described above with reference to 1-12 may be used alone without the other features and elements or in various combinations with or without other features and elements. Sub-elements of the methods and features described above with reference to FIG. 1-12 may be performed in any arbitrary order (including concurrently), in any combination or sub-combination. | An electronic information system which enables email based transactions comprises an information database storing information regarding a plurality of individuals in a group and selections available to individuals in the group. A first email message with a mail to hyperlink having a plurality of fields including actionable parameter is generated and sent. A reply email message is received in response to selection of the mail to hyperlink. The received email message includes the plurality of fields and the actionable parameter that indicates that a specific selection has been made. A processor performs the action indicated by the actionable parameter in response to the received email message, including updating the information database to indicate the specific selection that has been made. | 74,073 |
FIELD OF THE INVENTION
The present invention refers to a gob distributor for machines for the shaping of articles of glass or other materials which effectively and efficiently regulates the various movements of the distributor scoops towards respective shaping stations, which is of reduced size and easy to construct as compared with the known distributors, which can operate at higher speed of production by increasing the distance of fall of the gob between the feeder bowl and the scoops.
BACKGROUND OF THE INVENTION
In the manufacture of articles of glass or other materials molten glass is supplied in a continuous stream from a feeder bowl and is continuously cut by suitable cutters into portions known as gobs, which are distributed, by a gob distributor, to one or more cavities of a plurality of article-shaping stations, generally eight, which constitute the machine.
Gob distributors for distributing the gobs to the shaping sections of the machine for the manufacture of articles of glass are well known and have achieved very effective development during the last few years, so that this type of mechanism has become an extremely efficient unit which makes possible the formation of articles of glass in multiple-station machines, which has increased the production capacity to a great extent.
For example, U.S. Pat. No. 3,597,187 of Aug. 3, 1971, to Urban P. Trudeau assigned to Owens Illinois Inc. describes a molten glass gob distributor which comprises a pair of curved movable scoops supported on vertical shafts which by means of suitable gears are caused to turn through a predetermined angle of turn by a transverse bar which contains a cam follower which is pressed against the control cam, which has a shape such that it causes the curved scoops to turn simultaneously between one molding station and the next. The control cam in its turn is turned by means of a ring gear and a worm which is coupled to the shaft which is turned by a synchronous motor which turns the cam at a constant speed in synchronism with the operation controls, for instance the time drum which controls the various operations of each station of a multi-station machine for the shaping of glass articles.
In U.S. Pat. No. 3,721,544 of Mar. 20, 1973, to Wasyl Bystrianyk and Francis A. Sarkozy, assigned to Emhart Corporation, there is also described a distributor for gobs of molten glass which comprises essentially a pair of rotatable curved scoops, a mechanism for supporting the curved scoops in dependent relationship side by side in order to turn them on each of their vertical axes, which mechanism includes a ring spur gear adjacent to the upper end of each scoop, a horizontally extending slideable member supported in a housing which supports the mechanism and which at one end has a portion which defines a rack for coupling with the spur gears on the scoops in order to turn them and at its other end a cam follower which is compelled by a spring to follow the path of a rotating multilobe cam, each of the lobes having a predetermined lift which results in a reciprocating movement which defines the position at which the curved scoops turn.
This type of distributor has a cooling system for each scoop, consisting of a cooling passage of spiral configuration provided in a funnel-shaped portion.
The cooling liquid generally employed is water and it is introduced through an entrance gate and into an annular passage through a neck in which the ring gear is defined within the profiled spiral groove in the inner portion of the tubular funnel and from there upward and downward within an aligned passage defining the scoop portion, having a similar return portion with reference to the other scoop and funnel.
Finally, U.S. Pat. No. 3,775,083 of Nov. 27, 1973, to Nebelung et al., assigned to Emhart Corporation, describes and claims a gob distributor for machines for the forming of articles of glass which differs with regard to the manner of controlling the movement of the ring gears which in their turn move the shafts connected to the movable scoops since, in the particular case of the patent to Nebelung et al., such shafts are movable by means of ring gears which are connected to different racks, each of which is actuated by a fluid-driven linear motor, each one of which has a plurality of pistons which are driven through suitable distances and held by means of suitable stops in such a manner that a sequential movement can be imparted to each of the fluid-operated motors in order to enable the mechanism to move the scoops of the distributor between one station and the following one marked in the sequence by mere fluid pulses or signals instead of the use of the traditional cams which are employed both by Trudeau and by Bistrianyk. Nebelung, et al., however, use a plurality of individual pistons placed in tandem within respective pneumatic cylinders, which pistons are moved individually by air signals which come from each of the individual sections of the machine in order to move the distribution scoops in suitable sequence.
In this distribution system, the cooling of each distributor scoop is constituted by the walls in the portions of the funnels, which have cooling passages arranged in a spiral through which the cooling water is directed. The cooling fluid protects the support of the frame of the gearing, conducted from the outside and directed via the upper portion of a groove through the profile of each spiral scoop and from there to a cooling passage within the scoops, the manufacture of this type of distributor being rather complicated.
The problems which have been caused by the use of cooling passages for each scoop in the distribution of gobs of the different machines for the shaping of glass articles are known and reside essentially in the cooling of the bushings of the distributor scoops by means of a system of internal conduits of spiral configuration within the frame through which the cooling fluid is directed, its manufacture being more complicated and the size of the distributor being increased.
Another substantial disadvantage present resides in the fact that the present distribution units, because they are of larger size, occupy a greater amount of space between the feeder bowl which contains the molten glass and the different scoops of the shaping stations, thus preventing operation at higher speeds by shortening the distance of fall of the gob.
Another substantial disadvantage of the present distributors is that their manufacture is more complicated and their cost of manufacture greater.
SUMMARY OF THE INVENTION
A main object of the present invention is to provide a gob distributor for machines for the shaping of articles of glass or other materials which eliminates the liquid cooling system of the known distribution mechanism, replacing it with a cooling system which is less complicated.
Another object of the present invenion is to provide a gob distributor which does not require water-cooled bronze bushings.
Still another object of the present invention is, by reducing the space between the dosing source and the different channels of the shaping stations, to make it possible to work at higher speeds by increasing the height of fall of the gob.
Still another object of the present invention is that the size of the distributor is reduced to half that of the present distributors, its construction being less complicated.
A further object of the present invention is to provide a gob distributor which is of very great efficiency and precision and of lower competitive cost.
The above objects and others related thereto are obtained preferably, in accordance with the present invention, by providing a gob distributor for machines for the shaping of articles of glass which comprises in combination: a support housing or frame; fastening means rigidly coupled to the upper end of each curved distributor scoop; a drive member and an auxiliary member which firmly and turnably hold the curved distributing scoops between them by fastening means in dependent linear relationship; linking means which turn on a central shaft fastened to the housing or support frame which holds the distributor scoops aligned closely together side by side and which, through their fastening means, link and transmit the movement of the drive member inversely to the auxiliary member which acts as support, so as to permit the simultaneous synchronized turning of all the scoops; and a positioner coupled to the drive member in order to impart movements of advance and retraction to it so as to move the curved scoops simultaneously through an angle to selective positions of delivery in a programmed sequence, with precise movements between the different sections of the shaping machine.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features which are considered characteristic of the present invention will be set forth in detail in the accompanying claims. However, the invention itself, both on basis of its organization and its method of operation, together with additional objects and advantages thereof, will be better understood from the following description, read in conjunction with the accompanying drawings, in which:
FIG. 1 is a perspective view of the gob distributor of the present invention, showing a first arrangement for coupling with a positioner;
FIG. 2 shows the inner rack-gear coupling along the section B--B' of FIG. 1;
FIG. 3 shows the inner mechanism along a section A--A' through the distributor shown in FIG. 1;
FIG. 4 is a top plan view of the distributor shown in FIG. 1;
FIG. 5 is a convention perspective view of another embodiment of the present invention, showing a second arrangement for coupling with a positioner.
DETAILED DESCRIPTION
FIG. 1 shows the distributor 40 of the present invention which comprises essentially a support frame or housing 10 having four distributing scoops 15 arranged in tandem and each one having a gob receiver receiving gobs from a feeder bowl (not shown) in order to distribute them to the different forming sections (not shown) of the machine for the molding of glass articles. This set of scoops 15 is moved in synchronism by a drive rack 11 which is coupled to a positioner (not shown) in order to impart movement in a given synchronized sequence, in combination with an auxiliary rack 14.
Referring now to FIG. 2, a view along the section line B--B' of FIG. 1, there is seen a distributing scoop 15 which has coupled to it a ring gear 30 integrated with the upper part of the distributor scoop 15; this ring gear 30 is held firmly between an upper plate or flange 50 and a lower one 27; each scoop 15 is coupled between a pair of toothed racks 11 and 14; the toothed rack 11 is a drive rack which transmits its movement by means of the positioner (not shown) via the gear 30 to the auxiliary toothed rack 14 in order to move the scoops 15 in synchronism to the respective shaping sections (not shown). The drive rack 11 is supported by the frame 10 by means of a guide 29 which is fastened to the structure of the frame 10 and which makes it possible for the drive rack 11 to slide longitudinally. The auxiliary rack 14 also has a guide 25, not fixed, which makes it possible to adjust the play present between the two racks 11 and 14 and gears 30 due to the wear which they suffer, due to the constant movement, in the course of time. The guide 25 is adjusted by means of a compensating screw 24 for each scoop 15 and is supported by the frame 10.
The gears 30 are intercoupled to each scoop 15 by a lower plate or flange 27 which permits correct assembly between each gear 30 and scoop 15 and, as a result, upon the transmission of the movement via the drive rack 11, permits each scoop 15 to distribute in proper and orderly manner the gobs or batches of molten glass to the different forming sections of the machine. This connection between the ring gear 30 and the scoop 15 is effected via the fastening means 51 and 52.
In the lower part of the gear 30, located at the height of the plate 27 which connects the scoop 15 and the gear 30, there is a pan-shaped part 26 which makes it possible to recover the oil by gravity in a tank 35 and to be able to recirculate this oil for the lubrication of the inner mechanism of the distributor 40 and furthermore prevent its leaking out, for which there is furthermore interposed an oil seal ring 28 between the lower plate or flange 27 and the gear portion 30.
With respect to the upper part of the distributor 40 there is a cover 19 which bears, connected to it, a fixed funnel portion 21 for each distributor scoop 15, which avoids the diverting of the gob out of the distributor.
FIG. 3 shows a view along the section A--A' of FIG. 1 at least one gear 31, which may be coupled directly or indirectly to the frame 10 and the function of which is to impart synchronism to the auxiliary rack 14, providing support and movement to the gears 30 which, coupled with the scoops 15, comply with the movement of the drive rack 11, moving at the same time from one position to the other. This gear 31 is supported on the cover 19 of the distributor 40 by an inner bushing 20 which is rotatable on a pin 39 which is supported by separate fastening means 32, 53 on a plate 17. Through this gear 31, the drive rack 11 and the auxiliary rack 14 maintain the gears 30 aligned side by side and the movement of the drive rack 11 is transmitted to the auxiliary rack 14 to permit the synchronized turning of all the gears of the scoops.
The fastener 32 extends above the cover 19 of the distributor 40, said cover having a slot (not shown) which permits the sliding of the aforementioned gear 31 laterally of the cover when there is an adjustment between racks 11 and 14, by means of the guide 25 and screw 24, which are shown in FIG. 2.
FIG. 4 shows a plan view of the distributor 40 in which there can be seen the coupling present between the drive rack 11, the gears with their projecting plates 17 and 50 and the auxiliary rack 14.
Referring now to FIG. 1, coupling directly or indirectly to the frame 10 is an air cooling system 36 which makes it possible to cool the inner mechanism of the distributor 40 through the internal passages 23 shown in FIG. 2. This cooling by air will prevent the overheating of the gears 30 and both racks 11 and 14. Referring in particular to FIG. 5, there is shown therein another arrangement of the distributor 40 for coupling with a positioner of the fork type (not shown) which includes a connecting rod 60 articulately coupled at one of its ends to the drive rack 11.
As is well known in the art, the stream of molten glass issuing from the feeder bowl which is continuously cut into portions known as gobs, which are then distributed to the different forming sections (not shown) by means of the scoops 15 which move in synchronism from one position to the next via the drive rack 11 and the auxiliary rack 14 and which in a given sequence feed the gobs to the different sections of the machine for the shaping of glass articles.
It will be understood that the invention is not limited to the embodiment set forth above and that those skilled in the art will be able, based on the teaching of the present invention, to make changes in the design and distribution of the component parts of the invention which fall clearly within the true spirit and scope of the invention which is claimed in the following claims. | A gob distributor for glass-working machines in which the scoops are indexed angularly in unison by paired racks which provide the sole support and positioning members for the scoops. | 15,710 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process and an apparatus for continuously reacting liquid alkylene oxide with a liquid substance comprising an organic compound with one or more active hydrogen atoms and a catalyst selected from alkali metal hydroxides and alkali metal alcoholates, hereinafter also referred to as the “liquid catalyzed raw material”, in a reactor selected from
(a) a tubular reactor comprising at least one reaction tube providing a reaction space inside of said tube, and (b) an annular-gap reactor comprising an outer tube and an inner tube, longitudinally inserted into said outer tube, which form an annular reaction gap extending between the inner of the outer tube, which forms the outer boundary of the reaction gap, and the outer surface of the inner tube, which forms the inner boundary of the reaction gap.
2. Description of Related Art
DE 735 418 discloses a process, wherein a tube reactor comprising one reaction tube is used for a continuous alkoxylation of organic hydroxyl compounds, in particular alkyl phenols, and to a mixture of sodium hydroxide and said organic hydroxyl compound in parts at more than one location along the reaction tube. The distance of the locations for adding the liquid alkylene oxide from one another and the quantity of alkylene oxide supplied at the single locations is chosen such that the reaction temperature can be kept low enough, so that the reaction temperature in the tube does not significantly rise above 200° C. and undesired side reactions can be avoided. In case of working the process e.g. with two feeding locations for alkylene oxide, the organic hydroxyl compound is mixed with about one half of the total required amount of liquid alkylene oxide and the mixture is supplied with a high-pressure pump into a first section of the tube for reaction. After passing said first section, the reaction product is removed from the streaming tube and, after intermediate cooling, mixed with the remaining quantity of the required liquid alkylene oxide and this mixture is supplied with a further high-pressure pump to a second section of the streaming tube and is further reacted to the final product in said section which is then removed. The disclosed process however has many disadvantages including, in particular, that a reactor tube of 200 meter length is required, high pressures over 100 bar have to be maintained in the reaction tube in order to avoid an immediate vaporization of the supplied alkylene oxide and the quantity of alkylene oxide supplied at each feeding location has to be controlled by separate mass flow controllers. Furthermore, this reactor can only be used on a pilot plant scale where the use of a single reaction tube is sufficient, whereas the use of a bundle of reaction tubes, as required for production purposes, would require a multitude of alkylene oxide inlets in each reaction tube of the bundle, each with a mass flow controller. These technical efforts for controlling the alkoxylation are so expensive, that this process has never achieved acceptance in industrial practice.
DE 10054462 describes a similar continuous alkoxylation method, wherein relatively small quantities of liquid ethylene oxide are fed into a tubular reactor or in a tube bundle reactor at a large number of different locations along of the reaction tube (in the Example of this document e.g. at 15 locations). Feeding many small quantities of alkylene oxide is required in order to avoid a runaway of the reactor caused by uncontrolled reaction of the ethylene oxide at the feeding points because of the slow mixing speed of the reactants and the common cooling of all sections along the reaction tube which does not allow a specific control of the temperature in each section. In addition, this process design has again the disadvantage that the alkylene oxide flow is to be measured separately for each feeding location.
US 2008/0306295 claiming the priority of DE102005060816 describes a continuous multi-step process which is specifically designed for carrying out rapid, highly exothermic reactions between a gaseous and a liquid reactant, in particular for reacting a SO 3 /air mixture with liquid organic compounds including, among several other compounds, alkyl phenols and their alkylene oxide derivatives. The reaction is performed in a reactor selected from
(a) a tubular reactor comprising at least one reaction tube providing a reaction space inside of said tube, and
(b) an annular-gap reactor comprising an outer tube and an inner tube, longitudinally inserted into said outer tube, which form an annular reaction gap extending between the inner surface of the outer tube, which forms the outer boundary of the reaction gap, and the outer surface of the inner tube, which forms the inner boundary of the reaction gap,
which reactor (a) or (b) is a thin layer falling-film reactor and is connected with a source of a gaseous SO 3 /air mixture, wherein
(1) the gaseous SO 3 /air mixture is supplied to said reactor via a single inlet socket and the SO 3 /air mixture is split before entering the reaction space or gap into a first and second part (2) said first part of the SO 3 /air mixture enters the reaction space or gap of said reactor (a) or (b) at a first location, (3) the liquid organic compound is supplied as a film onto the inner surfaces of the at least one reaction tube of the tubular reactor (a) or onto the inner surface of the outer tube and/or onto the outer surface of the inner tube of the annular gap reactor (b) at a second location of the reactor, located downstream of said first location, and is brought into contact with the gaseous SO 3 /air mixture to form a liquid film of the reaction mixture of said reactants moving downstream on said surfaces towards the end of the reactor, and (4) the SO 3 /air mixture enters the reactor at said first location over the entire-cross sectional area of the reaction space or gap at said location, and (5) said second part of the SO 3 /air mixture is split off at said first location and is channeled from said first location to a third location in the reaction space or gap through a tube in case of a tube reactor (a) or through a double tube, respectively, in case of an annular gap reactor (b), which tube or double tube is inserted into the reaction space or gap, extends from said first location to said third location of the reactor space or gap, respectively, and has a diameter being smaller than the inner diameter of said reaction tube or outer boundary of said reaction gap, thus leaving a reaction space between the outer surface of said tube or double tube, respectively, on one side, and the inner surface of the reaction tube or the outer boundary of the reaction gap, respectively, on the other side, (6) said third location is located downstream of said second location, (7) said second part of the SO 3 /air mixture enters the reaction space or gap of the reactor at said third location and is brought into contact at said third location with the liquid film of the reaction mixture moving downstream on said surfaces towards the end of the reactor and reacts with it on its way to the outlet of the reactor to form the final reaction product.
The disclosed tube reactors have a length of about 10 m (tube diameter 1 inch) and the disclosed ring gap reactors have a length of about 2 m (6.5 mm annular gap width). Whereas reactors of such a length are useful for reacting organic hydroxyl compounds with the very reactive SO 3 gas, they have generally been considered to be much too short for reaction of such compounds with liquid alkylene oxides which are much less reactive than SO 3 gas.
SUMMARY OF THE INVENTION
It has now been surprisingly found, however, that reactors of the aforementioned design and length can also be used for alkoxylations of liquid organic materials with reactive hydrogen atoms, when some modifications are applied, and that a use of these modified reactors avoids the described disadvantages of the prior art alkoxylation processes, such as high temperature peaks, the danger of a formation of undesired by-products such as dioxane, dark colored end products, the requirement of working at pressures over 100 bar in the reactor, the limitation of many processes to alkoxylation grades of only 4-6 mole alkylene oxide per mole of the liquid organic raw compounds. These modifications include in particular the supply of the liquid organic material with reactive hydrogen atoms into the reactor in a way which almost immediately provides a very intensive mixing of the organic compounds with the liquid alkylkene oxide entered into the reactor, e.g. by use of ring slit nozzles for the supply of the liquid organic material with reactive hydrogen atoms. Further modifications include one or more of the use of static mixer elements at the locations where the reactants are fed into the reactor and downstream thereof which additionally improve the efficacy of the mixing process, the use of two or more separate tempering jackets which allow an efficient control of the reaction temperature in the reactor with a liquid cooling or heating medium and the use of a post reaction zone of a preferably increased inside width as compared to the reaction space. The shorter length of the reactor as compared to the reactors of the prior art with a length of about 200 m results in a very short residence time of the reaction mixture in the reactor (a few minutes as compared to up to 1 hour in the prior art reactor) which in turn results in a significantly reduced production of unwanted side products and accordingly in a significantly improved quality of the end product.
In a first aspect, the invention accordingly relates to a process for continuously reacting liquid alkylene oxide with a liquid substance comprising an organic compound with one or more active hydrogen atoms and a catalyst selected from alkali metal hydroxides and alkali metal alcoholates according to the present invention, wherein the process is performed in a reactor selected from
(a) a tubular reactor comprising at least one reaction tube providing a reaction space inside of said tube, and
(b) an annular-gap reactor comprising an outer tube and an inner tube, longitudinally inserted into said outer tube, which form an annular reaction gap extending between the inner surface of the outer tube, which forms the outer boundary of the reaction gap, and the outer surface of the inner tube, which forms the inner boundary of the reaction gap, and wherein
(1) the supply of liquid alkylene oxide to the reactor is controlled by a single mass flow controller, the liquid alkylene oxide is fed to said reactor (a) or (b) via a single inlet socket which is connected with a source of liquid alkylene oxide via said mass flow controller and the alkylene oxide is split before entering the reaction space or gap into a first and a second part and, optionally, further parts, (2) said first part of alkylene oxide enters the reaction space or gap of said reactor (a) or (b) at a first location, (3) the liquid organic substance is supplied to the interior of the reaction space of said tubular reactor (a) or to the interior of the reaction gap of said annular gap reactor (b) at a second location of the reactor, located at or downstream of said first location, and is intermingled with the liquid alkylene oxide to form a liquid reaction mixture, which moves downstream towards the end of the reactor, (4) the liquid alkylene oxide enters the reactor at said first location over the entire-cross sectional area of the reaction space or gap at said location, (5) said second and, optionally, further parts of alkylene oxide are split off at said first location or upstream thereof and are channeled from said first location to a third location and, when further parts of alkylene oxide are split off, to further locations in the reaction space or gap, through a separate tube for each part of alkylene oxide in case of a tube reactor (a), or through a separate double tube, respectively, in case of an annular gap reactor (b), which tube or double tube is inserted into the reaction space or gap, extends from said first location to said third or said further location of the reactor space or gap, respectively, and has a diameter being smaller than the inner diameter of said reaction tube or outer boundary of said reaction gap, thus leaving a reaction space between the outer surface of said tube or double tube, respectively, on one side, and the inner surface of the reaction tube or the outer boundary of the reaction gap, respectively, on the other side, (6) said third location and optional further locations are located downstream of said second location and have a distance from said second location and from each other in flow direction of the reactor charge, (7) said second and optional further parts of liquid alkylene oxide enter the reaction space or gap of the reactor at said third location and said optional further locations and are intermingled with said liquid reaction mixture and react with it on its way downstream towards the end of the reactor and (8) the inner pressure of the reactor is kept at a pressure level where alkylene oxide entering the reactor does not vaporize.
Furthermore, the present invention relates to an apparatus for continuously reacting liquid alkylene oxide with a liquid substance comprising an organic compound with one or more active hydrogen atoms and a catalyst selected from alkali metal hydroxides and alkali metal alcoholates, comprising a reactor selected from
(a) a tubular reactor comprising at least one reaction tube providing a reaction space inside of said tube, and
(b) an annular-gap reactor comprising an outer tube and an inner tube, longitudinally inserted into said outer tube, which form an annular reaction gap extending between the inner surface of the outer tube, which forms the outer boundary of the reaction gap, and the outer surface of the inner tube, which forms the inner boundary of the reaction gap,
and a source of liquid alkylene oxide which is connected via a single mass flow controller to a single inlet socket of said tubular reactor (a) or said annular gap reactor (b) for the alkylene oxide using a line for said alkylene oxide, wherein said reactor comprises
(1) at the reactor head an inlet for the alkylene oxide to the reaction space of the at least one reaction tube or the reaction gap of the annular gap reactor which extends over the entire cross-sectional area of the said reaction space or gap at a first location of said reaction space or gap, (2) a ring slit nozzle for feeding said liquid substance to the interior of the at least one reaction tube of the tubular reactor (a) and mixing it with alkylene oxide, which is located in said reaction tube at a second location at or downstream of said first location of the reaction space, or two ring slit nozzles for feeding said liquid substance to the interior of the reaction gap of said annular gap reactor (b) and mixing it with alkylene oxide, one ring slit nozzle being located in said outer tube and the other in said inner tube, which form the boundaries of the reaction gap, at a second location at or downstream of said first location of the reaction gap, (3) a first tube inserted into each of the at least one reaction tubes in case of a tubular reactor (a), or a double tube inserted into the reaction gap in case of an annular gap reactor (b), which extends from said first location or from a location upstream of said first location in direction of the outlet of said reactor for the reaction product to a third location in the reaction space or gap having a distance from said first and second location and, optional, further tubes inserted into each of the at least one reaction tubes in case of a tubular reactor (a), or further double tubes inserted into the reaction gap in case of an annular gap reactor (b), which further tubes or double tubes extend from said first location or from a location upstream of said first location in direction of the outlet of said reactor for the reaction product to other locations in the reaction space or gap having a distance from said third location and from one another in flow direction of the reactor charge, which first and optional further tubes channel liquid alkylene oxide from said first location to said third and other locations to dispense it at said location to the reaction space or gap, wherein said first and optional further tube(s) or double tube(s) have a diameter being smaller than the inner diameter of said reaction tube or outer boundary of said reaction gap, thus leaving reaction space between the outer surface of each tube or double tube, respectively, on one side, and the inner surface of the reaction tube or the outer boundary of the reaction gap, respectively, on the other side, (4) preferably, one or more static mixing element(s) located at said second location and, optionally, one or more further static mixing element(s) located between said second location and said third location in the reaction space or reaction gap for supporting the intermixture of the liquid alkylene oxide with said liquid substance and/or one or more static mixing element(s) located at said third and/or downstream of said third location in the reaction space or reaction gap for supporting the intermixture of the liquid alkylene oxide with said the liquid reaction mixture formed between said second and third location in the reactor, (5) preferably, two or more, more preferably three, separate tempering, i.e. cooling or heating jackets, which are consecutively in longitudinal direction of the reactor fitted to the reaction tube(s) of said tubular reactor (a) or to the outer and inner tube of the annular-gap reactor (b), the first one of said tempering jackets preferably being partially or completely located at a position between said second and third location, the second one preferably being located directly after said first tempering jacket and partially or completely after said third location and the optional third and further tempering jackets following consecutively after said second tempering jacket, and (6) an outlet for the reaction product at a location in the reaction space or gap which is downstream from all said other locations.
Although it is generally possible to divide the entire quantity of the alkylene oxide reactant into a multitude of parts which are fed at different locations to the reactor, a division into more than two parts is normally not necessary, because up to about 95 percent of the total required alkylene oxide can normally be supplied to the reactor space or gap at one location and the remainder can then easily be supplied at a second location. For example, it is possible to split the total quantity of liquid alkylene oxide reacted with the liquid substance so, that e.g. 10-90% of the alkylene oxide enter the reaction space or gap at the first location and the balance to 100% at said third location. In fact, it is just a particular advantage of the process according to the present invention that it is sufficient to split the total required amount of alkylene oxide into only two parts because, due to one or more measures which can be taken and which are described below, it is possible to control the reaction in a way that high temperature peaks, the danger of a formation of undesired by-products such as dioxane, dark colored end products, the requirement of using pressures of over 100 bar in the reactor and/or the limitation to alkoxylation grades of only 4-6 mole alkylene-oxide per mole of the liquid organic raw compounds can be avoided, although the entire required alkylene oxide is supplied at only two different locations of the reactor space or gap. Limitation to two locations for alkylene oxide and thus only one insert tube or double tube also simplifies the reactor design and is therefore also preferred in view of the reactor design and construction. The use of more than one insert tube or double tube, on the other hand, can additionally reduce the length of the reactors.
With respect to the mentioned preference for a two stage addition of the alkylene oxide to the reactor, many features of the process and apparatus according to the present invention are described in the following using the example of such a two stage process and a two stage reactor. It should be noted however that the described preferred measures can in most cases also be easily applied to a process or apparatus using three or even more different locations for supplying the alkylene oxide to the reactor space or gap and thus requiring two or more insert tubes or double tubes.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a representation of the principle of the invention for a two stage annular-gap reactor with mixing elements.
FIG. 1B is a representation of a two-stage annular gap reactor with a post reaction zone wherein the annular gap has a larger inside width than said main reaction gap of the reactor.
FIG. 2 is a representation of the principle of the invention for a two stage annular-gap reactor, top view.
FIG. 3 is a representation of the principle of the invention for a two-stage multi-tube reactor with mixing elements.
FIG. 4 is a representation of the principle of the invention for a two stage (multi) tube reactor, top view.
FIG. 5 shows the temperature progress in the reaction mixture and the cooling/heating temperature in the two stage annular gap reactor of Example 1.
FIG. 6 shows the partial pressure progress in the two stage annular gap reactor of Example 1.
DETAILED DESCRIPTION OF THE INVENTION
In its most general form, the apparatus according to the present invention comprises a source of liquid alkylene oxide which is connected with a line for said alkylene oxide and via a single mass flow controller to a single inlet socket for the alkylene oxide to the reactor located near to the reactor head. The inlet for the liquid alkylene oxide to the reactor space or gap (the main inlet for alkylene oxide) which is connected to said inlet socket and extends over the entire cross-sectional area of the reaction space or gap is located at or upstream of the inlet of the reactor space or gap for the liquid catalyzed raw material to be reacted with the alkylene oxide. The distance between said main inlet for the alkylene oxide and the inlet for the liquid compounds is not critical, but it is preferably rather small or even zero, so that the zone for reaction of the alkylene oxide with said raw material extends over as much of the length of the reactor as possible. The supply of further alkylene oxide to the reactor is effected over one or, optionally, more tubes which are inserted in the reaction tube or tubes of a tubular reactor and are smaller in diameter than the reaction tube(s) or, in case of an annular gap reactor, over one or, optionally, more double tubes inserted in the annular gap. If more than one insert tube or double tube is used, these tubes or double tubes are preferably concentric and the outer diameter of the different tubes or double tubes decreases with increasing length of the respective tubes. These inserted tube(s) or double tube(s) are placed such, that the entrance for liquid alkylene oxide into these tubes or double tubes is also located at or, preferably, upstream of the inlet for the liquid catalyzed raw material to the reaction space or gap of the reactor and preferably coincides with the main inlet for the alkylene oxide, whereas their outlets are located downstream of the inlet for the catalyzed raw material, so that fresh alkylene oxide is provided at the outlet of said tubes to the at least partially reacted mixture of the catalyzed raw materials and the alkylene oxide already supplied to the reaction space or gap upstream at the main inlet for alkylene oxide and at the outlets of any previously ending optionally present insert tubes or double tubes. This reactor design permits that the alkylene oxide addition is self-portioned because the distribution of the quantities of alkylene oxide supplied to the reaction mass at the different supply points in the reaction space or gap is defined by the ratio between the cross section of the insert tube of smallest diameter and the annular cross sections between each of the insert tubes and its neighboring larger insert tube or, finally, the reaction tube itself, in case of a tubular reactor, or by the ratio between the annular cross section of the inserted double tubes and the area corresponding to the sum of all annular cross sections between inserted double tubes, the annular cross section between the inner boundary of the annular gap and the insert double tube of smallest inner diameter and the annular cross section between the insert double tube of largest diameter and the outer boundary of the annular gap of the reactor. It is therefore sufficient to select insert tubes or double tubes of suitably selected dimensions for controlling the alkylene oxide addition to the reactor, so that expensive mass flow controllers for the alkylene oxide at each entry point are not necessary and only one is required for control of the overall quantity of alkylene oxide supplied to the reactor. The distribution of alkylene oxide to the further locations in the reaction space or gap with the inserted tube(s) or double tube(s) according to the invention permits that the supply of alkylene oxide can be performed with a single pump delivering the liquid alkylene oxide to the main inlet for alkylene oxide in the reactor head.
The catalyzed raw materials and, optionally, the alkylene oxide can be preheated in heat exchangers before entering the reactor, so that the entire reactor volume is used for the reaction only (and not for preheating). Suitable preheating temperatures for the catalyzed raw material range e.g. from 100 to 180° C., for the alkylene oxides e.g. from 20 to 60° C.
On the other hand, the liquid alkylene oxide which flows through an insert tube or double tube is preheated in any case on its way through these tubes or double tubes, which are located in the reaction zone, so that the further reaction of the already partially alkoxylated and thus less reactive material with the alkylene oxide is improved in a simple way. Simultaneously, the colder alkylene oxide in the insert tubes supports the removal of the reaction heat from the reaction mixture.
Due to a rather turbulent stream in the reaction space or gap the alkylene oxide, when supplied according to the invention in liquid form, is normally mixed with the catalyzed raw material immediately upon contact therewith.
In a particularly preferred embodiment of the process according to the present invention ring slit nozzles are used to feed the liquid organic substance into the interior of the reaction space of said tubular reactor (a) or to the interior of the reaction gap of said annular gap reactor (b). This technique further improves the efficiency and the speed of the intermixture of the liquid catalyzed raw material injected into the reaction space or gap with the alkylene oxide significantly.
Additionally, fixed (or static, what is used synonymously herein) mixing elements are preferably used for supporting and improving and further accelerating the mixing of the alkylene oxide with the raw material or partially reacted mass at the inlets for the alkylene oxide to the reaction space or gap or along the way of the reaction mass towards the outlet of the reactor. Static mixers are known and in use since about 50 years and are devices for mixing two fluid materials, most commonly, liquids. The device consists of mixing elements contained in a housing, e.g. a tube. These can vary in size from about 6 mm to several centimeters diameter. Static mixer elements consist of a series of baffles that are e.g. made from metal. Typical materials of construction for the static mixer components include e.g. stainless steel. E.g. two streams of liquids are delivered into the static mixer system. As these streams move through the mixer and the non-moving fixed mixing elements continuously blend the materials. Mixing is dependent on variables like the fluid properties, tube inner diameter, the number of elements, and the design of the mixing elements. Static mixer systems are also commercially available, e.g. from Robbins & Myers, Inc or Sulzer Chemtech Ltd (e.g. Sulzer SMX mixer, cf. Sulzer Technical Review 2+3/2009, 23-25). Static mixing elements are, according to the invention, preferably located at said second location, where the catalyzed raw material is injected into the reaction space or gap. Optionally, one or more further static mixing element(s) are located between said second location and at the mentioned third location in the reaction space or reaction gap, where the second part of liquid alkylene oxide is fed into the reactor for supporting the intermixture and reaction of the liquid alkylene oxide with liquid catalyzed raw material. Furthermore, one or more static mixing element(s) may be located at said third and/or downstream of said third location in the reaction space or reaction gap for supporting the intermixture of the liquid alkylene oxide with the liquid reaction mixture formed between said second and third location and/or at or downstream of the optional further locations in the reactor, where further liquid alkylene oxide is added to the reaction mixture.
The length of the insert tubes or double tubes defines the degree of reaction achieved during the single reaction zones, i.e. the shorter an insert tube or double tube is in general, the smaller is the degree of reaction taking place in the zone of the reaction space or gap of the reactor which is traversed by the respective tube or double tube and the larger is the residual conversion after said tube or double tube. Preferred reference values for the total length of the reactor space or gap range from about 2 to about 25 meters, preferably from about 5 to 10 meters, but can be different, of course, in certain cases. Preferred reference values for the length of the insert tubes or double tubes range from about 4 to 90 percent of the total length of the reaction space or gap.
Preferably, the reactor is furthermore equipped with two or more, more preferably three, separate tempering, i.e. cooling or heating jackets, which are consecutively in longitudinal direction of the reactor fitted to the reaction tube(s) of said tubular reactor (a) or to the outer and inner tube of the annular-gap reactor (b), the first one of said tempering jackets e.g. being partially or completely located at a position between said second and third location, the second one being located directly after said first tempering jacket and partially or completely after said third location and the optional third and further tempering jackets following consecutively after said second tempering jacket. In this way it is possible to control the temperature of the reaction mixture independently by liquid cooling or heating media of a suitable temperature present in said two, or optionally three or more separate tempering jackets in a way to avoid any local overheating of the reaction mixture and, on the other hand, to achieve a reaction of the alkylene oxide which is as complete as possible. Preferably, the temperature of the cooling/heating medium in the different sections is suitably adjusted to maintain the temperature of the reaction mixture in the reactor at the preferred level for this reaction, i.e. at 140-250° C., more preferably at 170-220° C. As indicated, it can be necessary to either heat the reaction mixture or to cool it in the different tempering zones.
In a further preferred embodiment of the process according to the present invention, the reaction mixture passes through an additional post reaction zone or space before leaving the reactor, which is located after the reaction tubes in case of a tubular reactor or after said annular reaction gap in case of an annular gap reactor (b) in a zone of the reactor following the main reaction zone, where the annular gap has preferably a larger inside width than said main reaction gap. The presence of a post reaction zone can significantly improve the final conversion rate of the alkylene oxide, so that end products with a residual content of unreacted alkylene oxide below e.g. 5 ppm or even below 1 ppm or less can be readily achieved. The post reaction space has preferably a volume of 0.5-5% of total volume of the reactor input (alkylene oxide+organic raw material). In case of a tubular reactor, one can consider the length of the main reaction zone to correspond to the distance between the location of the inlet for the liquid catalyzed raw material to the reaction space and the reaction tube ends. In case of an annular gap reactor the length of the main reaction zone can be considered to correspond to the distance between the location of the inlet for the liquid catalyzed raw material to the reaction gap and the begin of the zone of increased inside width of the annular gap when the post reaction zone has increased inside width. When the inside width of the annular gap is not increased in the post reaction zone, so that the main reaction zone invisibly switches over to the post reaction zone, the length of the main reaction zone can, for the purposes of the present invention, be considered to correspond to the distance between the location of the inlet for the liquid catalyzed raw material to the reaction gap and the end of the—in direction to the outlet of the reactor-last of the aforementioned tempering jackets mounted to the reactor.
A particular preferred embodiment of the process according to the present invention is performed in a reactor selected from
(a) a tubular reactor comprising at least one reaction tube providing a reaction space inside of said tube, and
(b) an annular-gap reactor comprising an outer tube and an inner tube, longitudinally inserted into said outer tube, which form an annular reaction gap extending between the inner surface of the outer tube, which forms the outer boundary of the reaction gap, and the outer surface of the inner tube, which forms the inner boundary of the reaction gap, and
(1) the supply of liquid alkylene oxide to the reactor is controlled by a single mass flow controller, the liquid alkylene oxide is fed to said reactor (a) or (b) via a single inlet socket which is connected with a source of liquid alkylene oxide via said mass flow controller and the alkylene oxide is split before entering the reaction space or gap into a first and a second part, (2) said first part of alkylene oxide enters the reaction space or gap of said reactor (a) or (b) at a first location, (3) the liquid organic substance is supplied to the interior of the reaction space of said tubular reactor (a) via a ring slit nozzle for feeding said liquid substance to the interior of the at least one reaction tube of the tubular reactor (a) and mixing it with the alkylene oxide, which is located in each of said reaction tubes at a second location at or downstream of said first location of the reaction space, or via two ring slit nozzles for feeding said liquid substance to the interior of the reaction gap of said annular gap reactor (b) and mixing it with the alkylene oxide, one ring slit nozzle being located in said outer tube and the other in said inner tube, which form the boundaries of the reaction gap, at a second location at or downstream of said first location of the reaction gap and is intermingled with the liquid alkylene oxide to form a liquid reaction mixture, which moves downstream towards the end of the reactor, (4) the liquid alkylene oxide enters the reactor at said first location and over the entire-cross sectional area of the reaction space or gap at said location, (5) said second part of alkylene oxide is split off at said first location or upstream thereof and is channeled from said first location to a third location in the reaction space or gap, through a tube in case of a tube reactor (a), or through a double tube, respectively, in case of an annular gap reactor (b), which tube or double tube is inserted into the reaction space or gap, extends from said first location to said third location of the reactor space or gap, respectively, and has a diameter being smaller than the inner diameter of said reaction tube or outer boundary of said reaction gap, thus leaving a reaction space between the outer surface of said tube or double tube, respectively, on one side, and the inner surface of the reaction tube or the outer boundary of the reaction gap, respectively, on the other side, (6) said third location is located downstream of said second location in flow direction of the reactor charge, (7) said second part of liquid alkylene oxide enters the reaction space or gap of the reactor at said third location and is intermingled with said liquid reaction mixture and reacts with it on its way downstream towards the end of the reactor, where it leaves the reactor through an outlet for the reaction product, and (8) the inner pressure of the reactor is kept at a pressure level where alkylene oxide entering the reactor does not vaporize, in particular at about 20 to 70 bar.
Further to the aforementioned process characteristics,
(9) the temperature of the reaction mixture is controlled in said particular preferred embodiment of the process according to the present invention by conveying liquid tempering media of suitable temperature through two or three separate tempering jackets, which are consecutively in longitudinal direction of the reactor fitted to the reaction tube(s) of said tubular reactor (a) or to the outer and inner tube of the annular-gap reactor (b), the first one of said tempering jackets being partially or completely located at a position between said second and third location, the second one being located directly after said first tempering jacket and partially or completely after said third location and the optional third tempering jacket follows consecutively after said second tempering jacket, (10) the intermixture of the liquid alkylene oxide with said liquid substance is additionally supported by one or more static mixing element(s) located at said second location and, optionally, by one or more further static mixing element(s) located between said second location and at said third location in the reaction space or reaction gap and/or the intermixture of the liquid alkylene oxide with said the liquid reaction mixture formed between said second and third location in the reactor is further supported by one or more static mixing element(s) located at said third and/or downstream of said third location in the reaction space or reaction gap, (11) the temperature of the reaction mixture in the reactor is maintained between 140 and 250° C., preferably 170-220° C., (12) the reaction mixture passes through an additional post reaction space before leaving the reactor, which is located after the reaction tubes in case of a tubular reactor or after said annular reaction gap in case of an annular gap reactor (b) in a zone of the reactor following the main reaction gap, where the annular gap has a larger inside width than said main reaction gap and (13) the residual alkylene oxide content of the material leaving the reactor is preferably below 1 ppm.
A preferred embodiment of the present invention uses a single insert tube or double tube and the cross-sectional area of said single tube or double tube is from 50 to 5% of the sum of said cross-sectional area and the cross-sectional area of the reaction space or gap at the first location.
Diverse organic materials can advantageously be reacted with alkylene oxide according to the process of the present invention. In particular, primary straight chain or branched fatty alcohols, e.g. straight chain native alcohols made from natural oils or fats like e.g. fatty alcohols marketed under the name Lorol (e.g. Lorol C12-14) as well as synthetic Ziegler alcohols, in particular straight chain alcohols made from ethylene like the C12-16 fatty alcohol marketed as Condea Alfol 12-16, and oxo-alcohols (alcohols that are prepared by adding carbon monoxide (CO) and hydrogen, usually combined together as synthesis gas, to an olefin to obtain an aldehyde using the hydroformylation reaction and then hydrogenating the aldehyde to obtain the alcohol, e.g. n-butanol, 2-ethylhexanol or isononylalkohol) can be alkoxylated. Unsaturated fatty alcohols can also be alkoxylated, such as tallow fatty alcohol. More rarely used are secondary alcohols. Furthermore, n-alkyl phenols or alkyl phenols with branched alkyl chains such as octyl phenol, nonyl phenol, tributyl phenol, fatty acids, fatty acid alkanol amides, fatty amines, hydroxy fatty acids containing neutral oils such as ricinus oil and fatty acid esters from poly hydroxy compounds can be used as starting material.
Manufacturing the catalyzed raw material is preferably performed continuously. A part of the liquid chemical compounds for alkoxylation is premixed with an aqueous alkali metal hydroxide solution or an alcoholic solution of an alkali metal alcoholate, preferably in a thin film evaporator. The water from the alkali metal hydroxide solution and the reaction water are removed at elevated temperatures under vacuum. Similarly, the alcohol from the alkali alcoholate solution and further alcohol generated during the alcoholate formation is removed at higher temperatures under vacuum to below 0.05 weight %. Therefore the formation of poly glycols or alkyl poly glycols is minimized. This premix is then mixed with the remaining of the liquid chemical compounds in a way that the catalyzed raw material contains about 0.1 to 1 mol-% of the catalyst. The catalyzed raw material can immediately be fed into the reactor and reacted with the alkylene oxide in order to avoid a temperature loss of said material.
Preferred alkylene oxides for the present invention are ethylene oxide, propylene oxide and mixtures thereof.
In a particular embodiment of the present invention alkyl phenols reacted with up to 9 moles ethylene oxide (EO) and more, e.g. 3 to 9 moles, tributyl phenol e.g. with about 7 moles ethylene oxide, and primary native and synthetic fatty alcohols e.g. with 2-3 mole ethylene oxide are produced, products which are frequently used in industrial practice for a further sulfonation. The latter product represents the main quantity of ethoxylated substances worldwide and is produced by subsequent sulfonation with SO 3 to the ether sulfates (lauryl ether sulphates), LES C 12-14 with 2-3 Mol EO, alcohol ether sulphates, AES C 12-14/15 with 2-3 Mol. EO. These ether sulfates are used e.g. in household products, personal care products, cosmetics, liquid dish wash detergents, shampoos and bubble bath. The total annual worldwide production of such sulfonated anionic surfactants is about 4,000,000 tons.
Furthermore, e.g. dimethyl fatty alkyl amine hydrochlorides can be alkoxylated, for example with 0.9 Mol ethylene oxide. In this case it is especially easy to perform the alkoxylation according to the process of the present invention, since the lower the molar amount of ethylene oxide used for the alkoxylation, the lower is the heat of reaction. It is clear, of course, that a suitable material of construction needs to be selected for the reactor which is resistant to the chloride ions of the raw material.
The alkoxylation process according to the present invention generally results in alkoxylation products having a particular narrow molecular weight distribution on contrary to processes wherein semi batch reactors are used which result in products having a much wider range of molecular weight distribution.
Particularly preferred for the purposes of the present invention is the use of a tubular reactor because this design is in general mechanically more stable.
A further important embodiment of the present invention is the continuous alkoxylation of catalyzed raw material as described above in an annular gap reactor with a single inserted double tube. This reactor design causes a division of the liquid alkylene oxide into three streams, one entering the reaction gap at the first location via the annular cross section I, extending from the outer surface of said inserted double tube to the outer boundary of the reaction gap, a second entering the reaction gap also at said first location via the annular cross section II, extending from the inner boundary of the reaction gap to the inner surface of an inserted double tube, and a third stream channeled through the insert double tube and entering the reaction gap at the outlet ending of said double tube.
For the purposes of the present invention this two-stage annular gap reactor is preferably dimensioned such that 10 to 90 percent of the alkylene oxide enter the reaction gap via the cross sections I and II and the balance to 100 percent through the insert double tube.
More preferably the insert double tube of the aforementioned gap reactor has a length of 4-70 percent of the length of the entire reaction gap of the reactor.
The design of this device is schematically shown in FIGS. 1A , 1 B and 2 (top view). An annular gap reactor is preferably 5 to 20 m long, more preferably about 5 to 15 m, the total inner width of the reaction gap is preferably between 5 and 15 mm. In an annular gap reactor consisting of two concentric jacketed tubes, an inner reactor tube ( 14 , 18 ) and an outer reactor tube ( 8 ) with an insert double tube ( 16 ) in the reaction gap (reaction chamber) ( 15 , 17 ). The jackets are designed with cooling/heating areas divided in three sections each. The liquid catalyzed raw material is supplied uniformly into the interior of the reaction gap through a ring-shaped distribution slit in the inner ( 4 ) and outer tube ( 11 ) (ring slit nozzles) ( 3 and 13 ). Preheated liquid alkylene oxide is applied over the reactor head ( 1 ), so that one part of alkylene oxide is fed directly via the two annular cross sections of the reaction gap ( 15 I and 15 II) at the first junction point defined by the outer wall of the inserted double tube and the inner wall of outer reaction tube and the outer wall of the inner reaction tube and the inner wall of the inserted double tube. The double tube is preferably inside-stabilized ( 22 ). The remaining alkylene oxide quantity enters the inserted double tube over a third annular cross section which forms the entrance of said double tube ( 16 ) and is channeled through said double tube to a lower point in the reaction gap ( 7 ) depending on the insert distance of the double tube in the reaction gap.
Preferably, the annular cross-sectional area of the inserted double tube at said first location is 90 to 10% of the sum of said cross-sectional area, the annular cross sectional area (I), extending from the outer surface of said inserted double tube to the outer boundary of the reaction gap, and the annular cross section (II), extending from the inner boundary of the reaction gap to the inner surface of an inserted double tube.
The alkylene oxide distribution system ( 2 ) is self proportioning corresponding to the two previously mentioned annular cross sections over which the alkylene oxide enters the reaction gap at the first junction point and the annular cross section at the entrance-side of the insert double tube. The second feeding point for alkylene oxide to the reaction gap is defined by the length of the inserted double tube ( 16 ). The entrance of the inserted double tube annular gap is located above the distribution slits (ring slit nozzles) for the liquid catalyzed raw material ( 3 and 13 ).
The turbulence at the alkylene oxide inlet points causes the liquid raw material charged over the inner ( 13 ) and outer ( 11 ) distribution slits (ring slit nozzles) to be promptly mixed homogenously with the alkylene oxide on its way down stream. The efficiency of the mixing is preferably improved by mixing elements ( 12 ) fixed within the reaction zone.
The three sections of the heat exchange jackets ( 6 ) of the inner and outer tube forming the reaction gap allow the control of the temperature of the process as required. The tempering (cooling or heating) medium is applied via inlets ( 5 ) and ( 21 ). The outlet of the medium occurs via manifolds ( 10 , 19 ). The reaction mix ( 20 ) leaves the reaction area ( 17 ) and is intermediately disposed in the residence chamber ( 9 ) where a post reaction follows (post reaction space). This product mix leaves the residence chamber and is led into a cyclone for removal of gaseous impurities of the raw material (hydrocarbons, aldehydes, CO 2 ) and other substances, which pollute the final product (alkylene oxide, dioxolane, dioxane). Thereafter, the final product is cooled and neutralized if necessary with for example lactic acid. A final filtration of this neutralized product may follow.
FIG. 1B shows an annular gap reactor as shown in FIG. 1A , wherein the inner boundary of the reaction gap in the post reaction zone of the reactor is formed by an inner tube having a smaller diameter than the tube forming the inner boundary of the main reaction gap resulting in a post reaction space ( 9 ) which has a larger inside width than said main reaction gap. The increased volume of the post reaction zone of the reactor contributes to decrease in reactor length without reducing the total residence time of the reaction mixture in the reactor and thus increasing the residual alkylene oxide content of the reaction product.
Another embodiment of the invention is the continuous alkoxylation of catalyzed raw material as described above in a special multi tube reactor. This multi tube reactor contains one smaller insert tube in each of its multiple reaction tubes. The liquid alkylene oxide is divided by virtue of the inserts into two streams. Preferably, the insert tubes of a multi tube reactor have a length of about 10 to 50 percent of the length of said reaction tubes.
An example design of this device is shown in more detail in FIGS. 3 and 4 .
The multi tube reactor for performing the alkoxylation consists, similar to a tubular heat exchanger, of a multitude of reaction tubes ( 8 ) and insert tubes ( 13 ) in the inner space at the top of each reactor tube. Each insert tube is preferably centered within the reaction tubes. The reactor is preferably 5 to 20 m long, more preferably about 5 to 15 m, in particular 5 to 10 m, the reaction tubes have preferably a diameter of 10 to 25 mm. The heat exchange-jacket or shell ( 5 ) with e.g. three different sections ( 6 ) allows controlling the temperature as required by the process. The liquid catalyzed raw material ( 4 ) is supplied uniformly via a special raw material distribution ( 3 ), in particular via ring slit nozzles located in the reaction tubes. The alkylene oxide is supplied to the reactor head ( 1 ) so that one part goes over the distribution chamber directly to the first alkylene oxide junction point of the reaction tube inlets ( 11 ) to a first reaction zone ( 12 ) in the reaction tubes and the remaining quantity goes over the inserted smaller tubes ( 13 ) to a lower second alkylene oxide junction point ( 7 ) and to a second reaction zone ( 14 ) positioned lower in the reactor. The self proportioning of the total supplied alkylene oxide occurs at location ( 2 ) corresponding to the cross section of the inserted tube ( 13 ) in relation to the annular area represented by the cross section of the reactor tube minus the cross section of the inserted tube.
The streaming speed of alkylene ethylene oxide and—preferably present—fixed mixing elements ( 17 ) in the annular gap formed by the tubes and the insert tubes cause immediate homogeneous mixing with the raw material supplied from the raw material distribution device ( 3 ). The three heat exchange sections allow individual control of the temperature. The cooling or heating medium, respectively, is supplied via the manifold ( 10 ). The medium outlet occurs through line ( 16 ). The reaction mix ( 15 ) from the second zone ( 14 ) of the reaction space flows through a final reaction chamber ( 9 ) for post reaction. A final degassing from remaining inert gases of the raw material like e.g. acetaldehyde or CO 2 , and from substances formed in the final product during the reaction, e.g. dioxane or dioxolanes, in a cyclone follows. Then, the final product is cooled and neutralized if necessary with lactic acid. If desired, the neutralized product can be filtered.
With this method, a reaction in two steps is realized, such as in a cascade. In the first step only a part of the stoichiometrically desired liquid alkylene oxide is supplied, in order to limit the amount of reacting material and thus the heat of reaction and the resulting temperature in the reactor, because only a partial reaction takes place, when the reaction starts with a smaller quantity of alkylene oxide than necessary for the final product (e.g. 70 percent, corresponding to a distribution of the amount of alkylene oxide of 70:30 between the two process steps). The development of reaction heat is therefore significantly smaller, so that a strong temperature increase in the first section of the reactor is avoided, and the reaction heat can be better removed by the cooling jacket. Due to this kind of processing, the exothermic reaction and the temperature behavior of an alkoxylation are much easier to control.
In case of annular gap reactors, in which the organic raw material is supplied via slits (ring slit nozzles) into the gap between the inner wall of the outer tube and the outer wall of the inner tube, a double tube is inserted in the annular gap (insert double tube) through which a part of the alkylene oxide is provided to the reaction gap further downstream and added to the mixture which has already partially been alkoxylated upstream in the reactor. In this way, a self-controlled proportioning of the total quantity of alkylene oxide intended for reaction with the catalyzed raw material into two parts is realized, corresponding to the relation between the sum of the partial annular cross-sections 15 I and 15 II (see FIG. 2 ) of the reaction gap and the annular cross-section of the insert double tube.
Depending on the length of the inserted double tube the conversion degree in the first part of the reactor and the residual conversion in the second zone can be adjusted.
A quite similar self-controlled alkylene oxide proportioning occurs in multi tube reactors according to the present invention. In each reaction tube of the multi tube reactor a smaller insert tube is inserted. A first part of the total quantity of alkylene oxide intended for reaction is supplied on top of each reaction tube via the annular space between reaction and insert tube and is directly brought into contact with the catalyzed raw material of the reaction tubes. The second portion of alkylene oxide reacts downstream after the end of the insert tubes in each of the reaction tubes with the already partially alkoxylated reaction product. The quantities of alkylene oxide added at the first supply location for alkylene oxide in each reaction tube and at the end of each insert tube are determined by the cross sections of the insert tube and the annular cross-section between the outer diameter of the insert tube and the inner diameter of the associated reaction tube. In this way, the reaction degree between first and second alkoxylation step is defined. Again, the conversion degree in the first part of the reactor and the residual conversion in the second zone can be adjusted by variation of the length of the insert tubes.
The length of the insert tube(s) in (multi) tube reactors or the insert double tube in annular gap reactors can e.g. range from 20 to 70 percent of the length of the reactor space or gap.
The insert tubes and insert double tubes are simple in design, and can be easily affixed to the reactors and centered in the reaction space or gap by spacers. These spacers also cause a turbulence and a mixing effect in the reaction material.
Moreover, due to the small reaction volume and the minimized portion of alkylene oxide in the reaction chamber, a previous inertization with nitrogen for safety reasons is not necessary.
The following Examples are provided for further illustration of the invention and shall not limit the scope of the invention. In particular, designing and sizing of the apparatus for different capacities is easily possible for persons of ordinary skill in the art. The reaction progress is shown in FIG. 5 (capacity, temperature development in the reaction mixture, cooling/heating temperatures). The ethylene oxide partial pressure development is shown in FIG. 6 .
EXAMPLES
Example 1
Reaction of n-nonyl phenol with 7 mole ethylene oxide in a 5 inch annular gap reactor of 5 m length with inserted double tube, with static mixing elements downstream the raw material input and at the second ethylene oxide input, with a length of 1.750 m (35% of the total reactor length) according to the invention with a capacity of 250.8 kg/h that corresponds to 2008 tons/year.
An annular gap reactor has a geometry according to FIGS. 1 and 2 , with an inner diameter of the outer tube of 5 inches=127.0 mm and an outer diameter of the inner tube of 114.0 mm and a reactor length of 5.000 m, with an annual gap width of 6.5 mm (annular space volume of 11.31 liters) and a supply for the liquid catalyzed raw material via a ring slit nozzle in the inner wall of the outer tube and another one in the outer wall of the inner tube. Both concentric tubes are jacketed tubes with three cooling or heating sections (see FIGS. 1 A/B), whereby the upper jacket section takes 35% of the entire jacket length, the middle jacket also 35% and the lower 30%. The annular gap (annular space) contains a thin-walled insert double tube. The wall thickness of the reactor is 10 mm (see FIG. 2 ), the gap of the cooling/heating zone amounts to 6 mm and the volume of the post reactor amounts to 0.02 m 3 . The wall thickness of the insert double tube (inner and outer tube shell) amounts to 0.5 mm, the outer diameter=122.67 mm, the inner diameter=118.33 mm, the distance from the outer and inner jacketed tube to the walls of the insert double tube amounts to (127−122.67)/2=2.17 mm and (118.33−114)/2=2.17 mm, respectively (see FIG. 1 ), the length of the insert double tube is 1.75 m (=35% of the total reactor length). The incorporated double tube diameters were dimensioned in this case so that the ethylene oxide is supplied about 82.25% through the two cross sections between outer and inner reactor tube and finally 17.75% through the incorporated double tube cross section.
For manufacturing the catalyst, a part of the total raw material n-nonyl phenol (MW=220) of 7.15 kg/h=0.0325 kmol/h and 0.38 kg/h of 50% caustic soda solution corresponding to 0.19 kg/h 100% caustic soda=0.0048 kmol/h=14.64 mol % appropriate to the n-nonyl phenol part are supplied after pre-mixing at a temperature of approx. 50° C. into a thin film evaporator (TFE) with an evaporator surface of 0.125 m 2 . The jacket temperature is adjusted with pressure reduced steam to 150° C.=approx. 4 bar (pressure controlled). The water quantity from the caustic soda solution and the reaction water (total approx. 0.28 kg/h) that is to be distilled off is released by a vacuum pump system with approx. 30 mbar absolute. The formed sodium-n-nonyl phenolate with a rest water content of <0.05% is taken out of the evacuated TFE by a special pump and fed through a self cleaning slit filter for removing impurities. After this procedure it is mixed in a static mixer with 97.36 kg/h=0.4425 kmol/h fresh n-nonyl phenol (this mixture contains then 1 mol % sodium-n-nonyl phenolate as catalyst).
In the annular gap reactor with inserted double tube according to the invention the pressurized cooling/hot water pre run temperature in the upper jacket is adjusted to 35° C. and the water loop quantity is set to 5 m 3 /h. The inlet temperature is kept constant by a “split range” automatic controller by monitored feeding of pressure steam, in case of preheating, and water, in case of cooling, into the pressure loop. In the middle jacket section the water loop quantity is adjusted to 5 m 3 /h and 55° C. and the same in the lower jacket.
The mixture of fresh n-nonyl phenol and the catalyzed n-nonyl phenol (the mixture now contains 0.6 mol % catalyst) is pumped by a special TFE discharge pump over a heat exchanger with a set temperature of 165° C. and over both distribution slits (ring slit nozzles) with a quantity in proportion to the gap of 104.62 kg/h n-nonyl phenol, including formed alcoholate as catalyst, controlled by mass flow meter into the space between the inner and outer concentric jacketed tubes. Over a supply pipe on the reactor head 146.32 kg/h=3.3257 kmol/h ethylene oxide (n-nonyl phenol related to ethylene oxide=1 to 7.0) are fed with a high pressure pump. Through the inserted double tube (1.750 m=35% of the total reactor length from top) a quantity of 25.37 kg/h (=17.75%) of the ethylene oxide flows and the remaining quantity of the ethylene oxide of about 120.35 kg/h (=82.25%) flows through the cross sections (I+II) (see FIG. 2 ) of the annular gap. The proportionate ethylene oxide conversion in the 1st section of the reactor (35% of reactor length) should be 25%, 35% in the 2nd section (35% of the reactor length) and 40% in the 3rd section (30% of the reactor length).
The reaction mixture at a temperature of approx. 236° C. exits the ring chamber (approx. 0.02 m 3 ) via a pressure control valve (50 bar) into a cyclone for degassing (inert gas from ethylene oxide, formed by-products e.g. dioxane). The gases are discharged then with a water ring vacuum pump and led to combustion or to a scrubber. In the cyclone a small vacuum is maintained at approx. 700 mbar absolute. If necessary, stripping steam can also be introduced into the cyclone. Hence a better degassing will be achieved. Afterwards the end product is cooled to approx. 60° C. in a heat exchanger with a recycle loop to the cyclone.
For neutralization with lactic acid (0.54 kg/h) by a dynamic mixer, the reaction mix is pumped over a heat exchanger in a loop with approx. 5 m 3 /h. The final product is discharged from the loop to the filtration or to the storage tank.
During start up of the alkoxylation reactor the procedure proceeds as follows: The annual gap reactor is first filled up with the concentrated, filtered catalyst mixture from the thin film evaporator and the fresh n-nonyl phenol mixed in a static mixer. The mixture containing 0.6 mol % catalyst is fed in the preset quantity per hour to the reactor after preheating to 165° C.
Immediately after achieving a low liquid level in the cyclone (level controlled) ethylene oxide, also in the preset quantity per hour, is pumped over the pre heater into the reactor. The pressure control valve in the reactor output line is adjusted to 50 bar (vapor pressure of ethylene oxide at 165° C. is approx. 50 bar). The temperature controllers for each section of the three heating/cooling loops of the reactor are adjusted to the required temperature.
Product Specification
Hydroxyl value (mg KOH/g): 106 calculated MW=528=7.0 mole EO
Color (visual): light yellow
Color (APHA): 20 max.
Density 50° C.: app. 1.04 g/cm 3
Pour point: 7° C.
Viscosity dynamic 50° C.: app. 65 mPas
Dioxane content (head space GC): max. 1 ppm
Ethylene oxide: max. 1 ppm
Polyglycol: 1%
Moisture (Karl Fischer): 0.05 weight %
Example 2
Reaction of n-nonyl phenol with 15 mole ethylene oxide in a 5 inch annular gap reactor of 5 m length with insert double tube, with static mixing elements downstream the raw material input and at the second ethylene oxide input, with a length of 1.750 m (35% of total reactor length) according to the invention with a capacity of 260 kg/h that corresponds to 2008 tons/year.
In comparison to Example 1 (7 mole ethylene oxide) the capacity is retained for the same reactor size. The reactor temperature is a little bit higher, since due to the higher ethylene oxide quantity (15 moles) the reaction heat increases. For the Example 2 the same annular gap reactor according to FIGS. 1 and 2 (dimensions as in Example 1) and the same thin film evaporator equipment as in Example 1 is used.
For manufacturing the catalyst a part of the total raw material (65 kg/h) n-nonyl phenol that means 4.45 kg/h=0.0202 kmol/h and 0.24 kg/h 50% NaOH solution corresponding to 0.12 kg/h 100% NaOH (caustic soda)=0.0030 kmol/h=14.64 mol % in relation to n-nonyl phenol, are both fed at 50° C. into a thin film evaporator (0.125 m 2 ) after pre-mixing. The thin film evaporator (TFE) is heated by 4 bar steam at approx. 150° C. (pressure controlled). The water quantities from caustic and the reaction water (in sum 0.17 kg/h) to be distilled off are exhausted by a water jet (30 mbar absolute). The sodium-n-nonyl phenolate with a residual water content of lower than 0.05% is taken out off the evacuated thin film evaporator by a gear pump and separated from impurities over a slit filter. Subsequently it is mixed in a static mixer with fresh n-nonyl phenol 60.55 kg/h corresponding to 0.2752 kmol/h (the blending then contains 0.6 mol % sodium-n-nonyl phenolate as catalyst).
The pressurized pre-run water temperature of cooling/heating in the upper reactor jacket section is fixed at 136° C., the water loop approx. at 5 m 3 /h. The entrance temperature is controlled by “split range” controlling which holds the temperature by injecting steam or cooling water into the loop. The middle jacket is connected to a water loop at 5 m 3 /h and 23° C. and the lower jacket is connected to a water loop at 5 m 3 /h and 35° C.
The discharge gear pump from the thin film evaporator pumps the catalyzed (0.6 mol %) n-nonyl phenol (65.07 kg/h, mass flow meter) over a heat exchanger with a set temperature of 165° C. through the inner- and outer distribution slits (ring slit nozzles) equally into the corresponding reaction space. Over the reactor head, 195.00 kg/h liquid ethylene oxide (=2.0683 kmol/h) is charged by a pressure pump (proportion n-nonyl phenol to ethylene oxide is 1:15). Dimensions of the insert double tube: Length 70% of the total reactor length, which means 3.500 m. Through the annular cross section of the jacketed concentric inner and outer tube (diameters d i =114 mm, d out =127 mm) 82.25%=160.39 kg/h is charged. Through the cross section of the insert double tube (Example 1) the residual quantity of ethylene oxide, which means 43.61 kg/h=17.75% is charged (3.5 m). The proportionate ethylene oxide conversion in the 1st section of the reactor (35% of the reactor length) should be 15%, 35% in the 2nd section (35% of the reactor length) and 50% in the 3rd section (30% of the reactor length).
The reaction mix exits the ring chamber (0.02 m 3 ) controlled via a pressure resistance valve to be degassed from the inert gases from ethylene oxide and formed by-products such as dioxane. Afterwards cooling to 60° C. follows in a heat exchanger and a recycling loop to a cyclone.
For neutralizing with lactic acid (0.34 kg/h) the reaction mix is pumped over a dynamic mixer and following cooler in a loop (5 m 3 /h). The final product from the neutralizer loop passes a filter and is discharged to the storage tanks.
Product Specification
Hydroxyl value (mg KOH/g): 63 calculated MW=880=15.0 mole EO
Color (visual): light yellow
Color (APHA): 20 max.
Density 50° C.: app. 1.07 g/cm 3
Pour point: 25° C.
Viscosity dynamic 50° C.: app. 80 mPas
Dioxane content (head space GC): max. 1 ppm
Ethylene oxide: max. 1 ppm
Polyglycol: 1%
Moisture (Karl Fischer): 0.05 weight %
Example 3
Preparation of n-nonyl phenol ethoxylate with 3 mole ethylene oxide in a 5 inch annular gap reactor of 5 m length with insert double tube, with static mixing elements downstream the raw material input and at the second ethylene oxide input, with a length of 1.750 m (35% of the total reactor length) according to the invention with a capacity of 704 kg/h, which corresponds to 5653 tons/year.
In comparison to Example 1 the throughput is raised above proportion due to the lower ethylene oxide part (3 mole) in the same reactor size, since the reaction heat is smaller.
For Example 3, the same annular gap reactor according to FIGS. 1 and 2 (dimensions as in Example 1 and the same thin film evaporator equipment as in Example 1) are used.
For catalyst manufacturing in Example 3, a part of the total raw material (440 kg/h) n-nonyl phenol that means 30.10 kg/h corresponding to 0.1368 kmol/h and 0.96 kg/h 50% NaOH solution equivalent to 0.480 kg/h 100% NaOH (caustic soda)=0.0120 kmol/h=8.78 mol % in relation to n-nonyl phenol, are both fed (after pre-mixing) at 50° C. into a thin film evaporator having an exchanger surface of 0.125 m 2 . The thin film evaporator is heated by 6 bar steam (pressure controlled). The water quantities from caustic and reaction (0.7 kg/h) to be distilled off are exhausted by a water jet (30 mbar absolute). The consisted sodium-n-nonyl phenolate with a residual water content of lower than 0.05% is removed from the evacuated thin film evaporator by a gear pump and filtered from pollution over a rotating slit filter. Thereafter the catalyst is mixed in a static mixer with fresh n-nonyl phenol 409.90 kg/h=1.8632 kmol/h (the mixture then contains 0.6 mol % sodium-n-nonyl phenolate).
The water supply temperature of cooling/heating in the upper reactor jacket is fixed at 75° C., the water loop approx. at 5 m 3 /h. The constant inlet temperature is controlled by “split range” controlling. The middle jacket admits a loop water quantity of 5 m 3 /h and 75° C. and the lower jacket operates at 5 m 3 /h and 75° C.
The discharge gear pump pumps the catalyzed (0.6 mol %) and fresh n-nonyl phenol (440.26 kg/h, by mass flow meter) from the thin film evaporator over a heat exchanger with a set temperature of 165° C. through the inner and outer distribution slits (ring slit nozzles) equally between the reactor walls. 264 kg/h liquid ethylene oxide=6.000 kmol/h is charged over the reactor head by a pressure pump (proportion n-nonyl phenol to ethylene oxide is 1:3). Dimensions of the insert double tube: Length 35% of the total reactor length means 1.750 m. Through the annular cross section of the jacketed concentric inner tube and outer tube (diameter d i =114 mm, d outer =127 mm) 82.25%=217.14 kg/h ethylene oxide is charged. Through the cross section of the insert double tube the residual quantity of ethylene oxide meaning 46.86 kg/h=17.75% is charged (1.75 m from first feed location). The proportionate ethylene oxide conversion in the first section of the reactor (35% of the reactor length) should be 20%, 40% in the 2nd section (35% of the reactor length) and 40% in the 3rd section (30% of the reactor length).
The reaction mix exits the ring chamber (0.02 m 3 ) controlled via a pressure resistance valve (adjusted pressure is 50 bar) and is degassed from the inert gases ethylene oxide and formed by-products such as dioxane. These gases are discharged under assistance of the water pump to combustion or a scrubber. Afterwards cooling to 60° C. follows in a heat exchanger and partial recycling to the cyclone.
For neutralizing with lactic acid (1.54 kg/h, 70% weight, molecular weight 90 g/mol) the reaction mix is pumped over a dynamic mixer and a following cooler in a loop (5 m 3 /h). The final product from the neutralizer loop is led to storage after passing a filter.
Product Specification
Hydroxyl value (mg KOH/g): 159.4 calculated MW=352=3.0 mole EO
Color (visual): light yellow
Color (APHA): 20 max.
Dioxane content (head space GC): max. 1 ppm
Ethylene oxide: max. 1 ppm
Polyglycol: 1%
Moisture (Karl Fischer): 0.05 weight %
Example 4
Preparation of n-nonyl phenol ethoxylate with 3 mole ethylene oxide in a 5 inch annular gap reactor, with static mixing elements downstream the raw material input and at the second ethylene oxide input, 10 m long with insert double tube of 6 m length (60% of the total reactor length) and 0.6 mol % NaOH as catalyst according to the invention with a capacity of 704 kg/h, which corresponds to 5653 tons/year.
Compared to Example 3 with the same capacity, the reactor length is increased up to 10 m. The reaction is now spread over a greater length, so that the temperature maximum then decreases to 209° C.
For Example 4 the same annular gap reactor according to FIGS. 1 and 2 (dimensions as in Example 1) is used.
Catalyst manufacturing for Example 4 was performed analogous to Example 3.
Under assistance of a gear pump the catalyzed n-nonyl phenol with 0.6 mol % caustic soda is pumped over a heat exchanger with a set temperature of 165° C. and equally supplied over both distribution slits (ring slit nozzles) between the inner and outer reaction tube. Over the reactor head 264.00 kg/h=6.000 kmol/h ethylene oxide is charged by a pump (n-nonyl phenol to ethylene oxide is 1:3). Through the insert double tube cross section (60% of the total reactor length=6.000 m) 46.86 kg/h=17.75% and 217.14 kg/h=82.25% of the ethylene oxide is charged over the annular cross sections shaped by the inner and outer reaction tube. The proportionate ethylene oxide conversion in the 1 st section of the reactor (35% of the reactor length) should be 40%, 40% in the 2nd section (35% of the reactor length) and 20% in the 3rd section (30% of the reactor length).
The reaction mix at 209° C. expands via a pressure control valve for degassing (inert gas from ethylene oxide and formed by-products e.g. dioxane) into a cyclone. After the degassing, cooling to 60° C. follows in a heat exchanger (recycling loop to cyclone).
The supply temperature of the pressurized (5 m 3 /h) cooling/heating water loop in the upper jacket is adjusted to 73° C. Maintaining the inlet temperatures for the three jackets (reaction sections) is done via a “split range” controller responsible for steam and cooling water feeding. The middle jacket water loop runs at 5 m 3 /h and 116° C. The lower jacket water loop runs at 5 m 3 /h and 141° C.
The reaction mix is pumped in a loop for neutralization with lactic acid (0.23 kg/h) over a dynamic mixer and a 5 m 3 /h cooler. After exiting the loop, the end product is led to the storage after filtering.
Product Specification
Hydroxyl value (mg KOH/g): 159.4 calculated MW=352=3.0 mole EO
Color (APHA): 20 max.
Dioxane content (head space GC): max. 1 ppm
Ethylene oxide: max. 1 ppm
Polyglycol: 1%
Example 5
Preparation of a fatty alcohol C 12-14 ethoxylate with 2 mole ethylene oxide in a 5 inch annular gap reactor, with static mixing elements downstream the raw material input and at the second ethylene oxide input, 10 m long with insert double tube of 6 m length (60% of the total reactor length) according to the invention with a capacity of 852 kg/h, which corresponds to 6816 tons/year.
In Example 5a fatty alcohol C 12 -C 14 is reacted with 2 mole of ethylene oxide. The output quantity in relation to Example 4 is increased using the same reactor size because due to the smaller ethylene oxide addition, less reaction heat is released. The temperature maximum then reaches 208° C. The average residence time in the reactor amounts to 55 seconds and 283 seconds in the post reactor (approx. 5 minutes total).
For Example 5, the same annular gap reactor in accordance with FIGS. 1 and 2 (dimensions as in Example 1) is used.
For the manufacturing of the catalyst a part of the total raw material (104.51 kg/h) fatty alcohol C 12-14 (C 12 =65-71%, C 14 =22-28%, C 16 =4-8%, molar weight=196 (from hydroxyl value) that means 40.22 kg/h=0.2052 kmol/h and 1.44 kg/h 50% caustic soda solution=0.72 kg/h 100% NaOH=0.0180 kmol/h equivalent to 8.77 mol % related to the part fatty alcohol C 12-14 , is fed after pre-mixing at a temperature of approx. 50° C. into a thin film evaporator (TFE) with an evaporator surface of 0.125 m 2 . The jacket temperature of the TFE is adjusted by pressure steam to 150° C.=approx. 4 bar (pressure control). The water from the caustic soda solution and the reaction water (in sum approx. 1.04 kg/h) to be distilled off is exhausted by a water ring pump (vacuum approx. 30 mbar). The formed sodium C 12-14 -fatty alcoholate with a rest water content of <0.05% is taken out of the vacuum by a special pump and passes a slit filter to separate impurities. Then the filtrate is mixed in a static mixer with fresh fatty alcohol C 12-14 547.78 kg/h=2.705 kmol/h (the blending contains then 0.6 mol % sodium C 12-14 alcoholate as catalyst).
Under assistance of a gear pump the catalyzed fatty alcohol C 12-14 is led over a heat exchanger with a set temperature of 165° C. and is evenly led over the two distributor slits (ring slit nozzles) into the gap between the walls of the two concentric reaction tubes. Via a feed pipe at the reactor head 264.00 kg/h ethylene oxide (=6.000 kmol/h) (relationship fatty alcohol C 12-14 to ethylene oxide=1 to 2) is supplied by a high pressure pump. Through the inserted double tube (60% of the total length of the reactor=6.000 m) and over the above mentioned two cross sections of the annular gaps and the inserted double tube 82.25%=217.14 kg/h of the ethylene oxide are supplied between the annular gaps inside and outside of the inserted double tube. Over the inserted double tube the remaining quantity of ethylene oxide 46.86 kg/h=17.75% follows after 6.000 m from the reactor top. The proportionate ethylene oxide conversion achieves 40% in the 1 st part of the reactor (35% of the reactor length), 40% in the 2 nd part (35% of the reactor length) and 20% in the 3 rd (30% of the reactor length). The reaction mixture exits the reactor end at 208° C. and is then discharged from the ring chamber (approx. 0.02 m 3 ) via a pressure control valve into a cyclone for degassing (inert gases from the EO, formed by-products e.g. dioxane). Afterwards cooling down to approx. 60° C. takes place in a heat exchanger by a recycle loop to the cyclone.
The pressurized heating/cooling water supply temperature in the upper jacket was adjusted to 85° C. by a loop quantity of 5 m 3 /h. The inlet temperatures for each section is kept constant by a “split range” automatically controlled feeding of steam or cooling water supply into the pressure water loop. In the middle jacket section the loop quantity is adjusted to 5 m 3 /h water at 129° C., and in the lower jacket the water loop quantity is adjusted to 5 m 3 /h and 153° C.
For neutralization with lactic acid (2.31 kg/h), the reaction mixture is pumped in a loop over a dynamic mixer and following cooler (loop quantity approx. 5 m 3 /h). From the neutralization loop, the final product is led to storage after filtering.
If the reaction mixture is supplied directly to a sulfation plant, neutralization with lactic acid is not necessary. The un-neutralized product can be stored temporarily in buffer vessel under a nitrogen blanket.
Example 6
Preparation of a fatty alcohol C 12-14 ethoxylate with 3 mole ethylene oxide in a 36 inch annular gap reactor, with static mixing elements downstream the raw material input and at the second ethylene oxide input, 10 m long with insert double tube of 6 m length (60% of the total reactor length) and 1 mol % catalyst according to the invention with a capacity of 4920 kg/h, which corresponds to 39360 tons/year.
Compared to Example 3, the ethoxylation is performed in a 36 inch annular gap reactor with a length of 10 m and a catalyst concentration of 1 mol % and a length of the inserted double tube of 6 m length (60% of the total length). Here the reactor is used for pre-heating of ethylene oxide and fatty alcohol. The feed temperature of ethylene oxide is 20° C. and the temperature of the fatty alcohol is 40° C.
The annular gap reactor according to FIGS. 1 and 2 consists of an outer tube with an inner diameter of 36 inches=914.4 mm and an inner tube with an outer diameter of 895.2 mm, and a reactor length of 10 m, with an annular width of 9.6 mm (annular space volume is 0.272 m 3 ) and a raw material distributor slit (ring slit nozzle) in the inner and outer jacketed reaction tubes with three cooling/heating sections (see FIG. 1 ). The upper and middle jackets cover each 35% and the lower jacket covers 30% of the total reactor length. In the annular gap (annular space) a thin-walled double tube is incorporated. The wall thickness of the reactor amounts to 19 mm, the gap of the cooling/heating jackets is 8 mm and the volume of the post reactor amounts to 0.08 m 3 . The wall thickness of the insert double tube is 0.5 mm, the outer diameter is 908.0 mm, the inner diameter is 901.6 mm, and the slit width amounts to (908.0−901.60)/2=3.20 mm. The length of the insert double tube amounts to 6 m=60% of the total reactor length.
The diameter of the insert double tube is dimensioned such that 77.08% of the ethylene oxide is charged over the inner and outer annular gap and the remaining 22.92% over the insert double tube.
To manufacture the catalyst for Example 6, a part of the total raw material (2940.00 kg/h) fatty alcohol C 12-14 (C 12 =65-71%, C 14 =22-28%, C16=4-8%, molar weight=196 (from hydroxyl value) namely 201.11 kg/h=1.0261 kmol/h and 12.00 kg/h 50% caustic soda solution=6.00 kg/h 100% NaOH equivalent to 0.15 kmol/h=14.62 mol % related to fatty alcohol C 12-14 . All together is fed after pre-mixing at a temperature of approx. 50° C. into a thin film evaporator (TFE) with a vaporizer surface of 1.0 m 2 . The jacket temperature of the TFE is set by steam to 150° C.=approx. 4 bar (pressure controlled). The water from the caustic soda solution and the reaction water (in sum approx. 8.70 kg/h) to be distilled off is sucked out by a water jet pump under a vacuum of approx. 30 mbar. The formed sodium—fatty alcoholate C 12-14 with a rest water content of <0.05% is pumped out of the evacuated TFE and led over a slit filter to remove pollution. Then it is mixed in a static mixer with 2738.89 kg/h=13.9739 kmol/h fresh fatty alcohol C 12-14 (this mixture then contains 1.0 mol % sodium fatty alcoholate C 12-14 .)
The supply temperature of the pressurized cooling/heating water loop with 10 m 3 /h is set in the upper jacket section at 112° C. The entrance temperature is adjusted under assistance of a “split range” control for supply of steam (especially for preheating) with constant pressure or cooling water into the pressure water loop. For the middle jacket a pressurized water loop of 10 m 3 /h and 150° C. is adjusted and also a 10 m 3 /h water loop with 150° C. for the lower section.
With a gear pump the fatty alcoholate C 12-14 , catalyzed with 1.0 mol % is preheated over a heat exchanger to a temperature of 165° C. and charged over the two distributor slits (ring slit nozzles) with a quantity of 2943.30 kg/h (mass flow meter) fatty alcoholate C 12-14 (including formed alcoholate, which is the catalyst) evenly between the inner and outer reaction tube walls. Over a manifold on the reactor top 1980 kg/h=45.00 kmol/h ethylene oxide (relation fatty alcoholate C 12-14 to ethylene oxide=1 to 3) is charged by a pressure pump. Through the insert double tube (60% of the total length of the reactor=6.000 m) and over the previously mentioned annular gap cross sections inside and outside of the inserted double tube ethylene oxide is charged over the annular gaps (77.08%=1526.18 kg/h). The remaining quantity of ethylene oxide 453.82 kg/h=22.92% runs through the insert double tube approx. 6.000 m lower. The proportionate ethylene oxide conversion in the 1 st part of the reactor (35% of the reactor length) should be 57%, 28% in the 2 nd part (35% of the reactor length) and 15% in the 3 rd (30% of the reactor length). The reaction mixture then exits the post reactor (ring chamber approx. 0.08 m 3 ) via a pressure control valve (adjusted to 50 bar) into a cyclone for degassing (inert gases from the EO, formed by-products e.g. dioxane). The waste gas exhausted by a water ring vacuum pump can be led to combustion or to a scrubber. Subsequently the cooling to approx. 60° C. takes place in a heat exchanger in the recycling loop to the cyclone.
For neutralization with 19.29 kg/h 70 weight % lactic acid (mole weight=90) the reaction mix is pumped over a dynamic mixer and passes a cooler in a loop (approx. 10 m 3 /h). The final product exiting the neutralizer loop flows into the storage tanks after filtering.
Example 7
Preparation of n-nonyl phenol ethoxylate with 3 mole ethylene oxide in a 36 inch annular gap reactor, with static mixing elements downstream the raw material input and at the second ethylene oxide input, 10 m long with insert double tube of 5.500 m length (55% of the total reactor length) and 1 mol % catalyst according to the invention with a capacity of 5707 kg/h, which corresponds to 45656 tons/year.
Compared with Example 6, the ethoxylation is performed in a 36 inch annular gap reactor with a length of 10 m and a catalyst concentration of 1 mol % and a length of the inserted double tube of 5.5 m (55% of the total length). In this case the reactor is used concurrently for pre heating of the ethylene oxide and fatty alcohol. The feeding temperature of the ethylene oxide is 20° C., and the temperature of the fatty alcohol with 1 mol % catalyst is 40° C.
The annular gap reactor according to FIGS. 1 and 2 consists of an outer tube with an inner diameter of 36 inches=914.4 mm and an inner tube with an outer diameter of 895.2 mm, and a reactor length of 10 m; with an annular width of 9.6 mm (annular space volume is 0.272 m 3 ) and a raw material distributor slit (rings slit nozzle) in the inner and outer jacketed reaction tube and three cooling/heating sections (see FIG. 1 ). The upper and middle jackets each cover 35% and the lower jacket covers 30% of total reactor length. In the annular gap (annular space) a thin-walled double tube is incorporated. The inner and outer wall thickness of the reactor amounts to 19 mm, the gap of the cooling/heating jackets amounts to 8 mm and the volume of the post reactor amounts to 0.08 m 3 . The inner and outer wall thickness of the insert double tube is 0.5 mm, the outer diameter is 908.0 mm, the inner diameter is 901.6 mm, so that the gap width amounts to (908.0−901.60)/2=3.20 mm. The length of the insert double tube amounts to 5.500 m=55% of the total reactor length. The diameter of the insert double tube is dimensioned so that 77.08% of the ethylene oxide is charged over the inner and outer annular gap and the remaining 22.92% over the insert double tube cross section.
To manufacture the catalyst for Example 7, a part of the total raw material=3410.00 kg/h fatty alcohol C 12-14 (C 12 =65-71%, C 14 =22-28%, C 16 =4-8%, molar weight=196 (from hydroxyl value) namely 233.26 kg/h=1.1901 kmol/h and 13.92 kg/h 50% caustic soda solution=6.96 kg/h 100% NaOH=0.1740 kmol/h=14.62 mol % related on fatty alcohol C 12-14 . All is pre-mixed and fed at a temperature of approx. 50° C. into a thin film evaporator (TFE) with a surface of 1.0 m 2 . The jacket temperature of the TFE is set by steam to 150° C.=approx. 4 bar (pressure controlled). The water from the caustic soda solution and the reaction water (in sum approx. 10.09 kg/h) to be distilled off is sucked out by a water jet pump under a vacuum of approx. 30 mbar. The formed sodium—fatty alcoholate C 12-14 with a rest water content of <0.05% is pumped out of the evacuated TFE and led over a slit to filter from pollution. Then it is mixed in a static mixer with 3176.74 kg/h=16.2078 kmol/h fresh fatty alcohol C 12-14 This mixture then contains 1.0 mol % sodium-fatty alcoholate C 12-14 as catalyst. The temperature of the mixture is 48° C.
The supply temperature of the pressurized cooling/heating water loop is set in the upper jacket section at 179° C. The loop quantity of water amounts to 10 m 3 /h. The entrance temperature is adjusted with assistance of a “split range” controlled steam pressure (especially for preheating) or cooling water supply into the pressure water loop. For the middle jacket a water loop of 10 m 3 /h and 113° C. is adjusted and for the lower jacket section a water loop with 167° C. is used.
By means of a gear pump the fatty alcoholate C 12-14 , catalyzed with 1.0 mol % is charged over the two distributor slits (ring slit nozzles) in the inner and outer jacketed concentric reactor tubes with a quantity of 5710.83 kg/h (mass flow meter) with a mixing temperature of 48° C. equally between the inner and outer reaction tube walls. Over a head manifold on the reactor top 2297 kg/h ethylene oxide (=52.2045 kmol/h) (relation fatty alcoholate C 12-14 to ethylene oxide=1 to 3) is charged by a pressure pump. Through the insert double tube (55% of the total reactor length 5.500 m) and over the previously mentioned annular gap cross sections inside and outside of the inserted double tube ethylene oxide is charged (77.08%=1770.53 kg/h). The remaining quantity of ethylene oxide 526.47 kg/h=22.92% is charged through the insert double tube approx. 5.500 m below the top. The proportionate ethylene oxide conversion in the 1 st part of the reactor (35% of the reactor length) should be 20%, 55% in the 2nd part (35% of the reactor length) and 25% in the 3rd (30% of the reactor length). The reaction mixture then exits the post reactor (ring chamber approx. 0.08 m 3 ) via a pressure control valve (adjusted pressure 50 bar) into a cyclone for degassing (inert gases from the ethylene oxide, formed by-products e.g. dioxane). The waste gas exhausted by a water ring vacuum pump can be led to combustion or to a scrubber. Subsequently cooling down to approx. 60° C. takes place by a heat exchanger in a recycling loop to the cyclone.
For neutralization with 22.37 kg/h 70% lactic acid (mole weight=90) the reaction mix is pumped over a dynamic mixer and passes a cooler in a loop (approx. 10 m 3 /h). The final product exits the neutralizer loop and flows into the storage tanks after filtering. | Disclosed is a process for continuously reacting liquid alkylene oxide with a liquid substance including an organic compound with active hydrogen atoms and a catalyst in a reactor. | 91,941 |
This application is a continuation of Ser. No. 604,540, filed Oct. 29, 1990, now abandoned, which is a continuation of application Ser. No. 07/244,273filed Sept. 14, 1988 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an electronic blackboard system which is capable of processing as electric signals various types of information such as written information, erased information and designated information on a writing surface using a writing instrument, an eraser, and a designating rod and of outputting necessary information to an output unit.
2. Description of the Prior Art
As a conventional apparatus of this type, the present applicant already proposed one disclosed in Japanese Patent Application No. 2736/1986 "Electronic Blackboard Apparatus" (refer to Japanese Patent Laid-Open No. 160299/1987). A brief description thereof will be given.
A blackboard body comprises a tablet and a casing which is made of a non-magnetic material and whose surface is formed as a writing surface which can be used repeatedly. The tablet is arranged such that a multiplicity of position detecting members each mainly composed of an elongated magnetostrictive transmission medium element made of an amorphous alloy or the like, a first coil wound around one end thereof, and a second coil wound around the substantially entire length thereof are arranged in parallel in the X- and Y-directions.
If a pulse current is applied to the first coil, fluctuations in the magnetic field occur around the first coil due to the action of electromagnetic conversion, with the result that magnetostrictive vibratory waves are produced in the magnetostrictive transmission medium element. The magnetostrictive waves propagate through the magnetostrictive transmission medium element at a peculiar speed, and, in the mean time, fluctuations in the magnetic field corresponding to an electrical/mechanical coupling coefficient at each position.
To depict an image, if a magnetism generator for producing a steady magnetic bias, such as a marker or an eraser each having a magnet, is operated, the magnetic bias is applied to the magnetostrictive medium element, and the electrical mechanical coupling coefficient at that position is increased. For this reason, when the magnetostrictive vibratory waves reach the position immediately below the marker or the eraser, large fluctuations occur in the magnetic field, and a large induced voltage occurs in the second coil.
The time required from application of a pulse current to the first coil until the generation of a large induced voltage in the second coil is the time required as the magnetostrictive vibratory waves propagate from the position at which the first coil is wound around the magnetostrictive medium element to the position immediately below the marker or the eraser, and is proportional to the distance therebetween. Hence, if this time is measured, the coordinates of the marker or the eraser are detected.
If a comparison is made between the function of the marker and that of an eraser, the marker forms an image on the writing surface, while the eraser erases an image on the writing surface. Since their functions are utterly different, in order to obtain an image data corresponding to an image used for the marker and that for the eraser, it is necessary to accurately discriminate the coordinates for the marker and those for the eraser.
In the above-described apparatus, infrared-ray signals respectively having different frequencies are transmitted from the marker and the eraser when they are used, and these signals are received by the blackboard body. Thus, discrimination is made on the basis of the frequency as to whether the marker is being used or the eraser is being used.
With the above-described arrangement, however, it is necessary to provide the marker and the eraser with infrared ray-emitting elements, oscillation modulation circuits, switches, and batteries for operating them. Hence, there has been drawbacks in that the arrangement becomes complicated, large is size and weight, and that replacement or charging of the batteries must be carried out frequently, thereby aggravating the operating efficiency of the marker and the eraser.
In addition, the coordinates obtained as described above are normally stored in a predetermined image memory as image data corresponding to the image formed on the writing surface by the writing instrument. However, the image data is output from a printer as a hard copy, as necessary, or displaced on a display device connected to the apparatus, or transmitted to another similar electronic blackboard apparatus installed in a remote place via a communication line so as to be displayed on a display device thereof.
When a lecture is given by using an electronic board, there are cases where it is desirable to proceed with the lecture by indicating a desired position on the image on the writing surface with a finger or a rod-shaped instrument.
However, in the case of the above-described electronic board apparatus, there has been a drawback in that a person who is looking at the writing surface of the blackboard body can recognize the indicated position, but the indicated position cannot be known to the person who is viewing the display device.
SUMMARY OF THE INVENTION
To this end, a primary object of the present invention is to provide a new and improved blackboard system having a marker and an eraser which do not require a cord, a battery or the like and excels in the operating efficiency.
To this end, the present invention provides, in accordance with one aspect of the invention, the combination of a coil, plural objects adapted to be selectively in proximity to the coil, and means for supplying AC energy at different frequencies to the coil. Each of the objects includes a tuned circuit having a different resonant frequency. The tuned circuit on the particular object in proximity to the coil has substantially the same resonant frequency as the AC energy supplied to the coil to cause a change in the current flowing in the coil at said same frequency. The change in the current flowing in the coil at the same resonant frequency is sensed. In response to the current change at the same resonant frequency the particular object having the tuned circuit with the same resonant frequency as the frequency of the applied AC energy is indicated with a phase detector-means. The phase detector means responds to the changed current flowing in the coil at the same resonant frequency and a reference wave at the same resonant frequency for: (a) deriving indications of the polarities of the phase of quadrature components of the changed current relative to the reference wave, and (b) indicating the durations of the polarity indications relative to predetermined values therefor.
The invention is also directed to apparatus for determining which one of plural objects is in proximity to a region, wherein each of the objects includes a tuned circuit having a different resonant frequency. The apparatus comprises a coil in the region, means for supplying AC energy at different resonant frequencies in the coil, and means for sensing the change in the current flowing in the coil at the same resonant frequency and responding to the current change at the same resonant frequency and responding to the current change at the same resonant frequency to indicate the particular object having the tuned circuit with the same resonant frequency as the frequency of the applied AC energy. The tuned circuit on the particular object in the region has substantially the same resonant frequency as the AC energy supplied to the coil causing a change in the current flowing in the coil at said same frequency. The sensing means includes phase detector means responsive to the changed current flowing in the coil at said same frequency and a reference wave at the same resonant frequency for; (a) deriving indications of the polarities of the phase of quadrature components of the changed current relative to the reference wave, and (b) indicating the durations of the polarities responsive to predetermined values therefor.
In a preferred embodiment, the phase detector means includes: (a) first and second phase detectors for deriving d.c. signals having polarities indicative of said indications of the polarities, (b) separate pulse width detectors responsive to said first and second polarities for deriving binary levels indicative of the polarities subsisting for in excess of a predetermined duration, and (c) gate means responsive to said pulse width detectors.
Each of the separate pulse width detectors preferably includes first and second comparators for deriving first and second bi-level signals having durations equal to the intervals while the d.c. signals respectively have the first and second polarities. The separate pulse width detectors include first and second pulse width detectors respectively responsive to the first and second bi-level signals derived by the first and second comparators.
The other objects, features and advantages of the present invention will become apparent from the following detailed description of the invention when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is diagram illustrating a first embodiment of an electronic blackboard system in accordance with the present invention;
FIG. 2 is a top plan view illustrating a structure of a tablet;
FIG. 3 is a cross-sectional view taken along the line III--III of FIG. 2;
FIG. 4 is characteristic diagram of a magnetic bias vis-a-vis an electrical/mechanical coupling coefficient;
FIG. 5 is a cross-sectional view of a marker;
FIG. 6 is a cross-sectional view of an eraser;
FIG. 7 is a cross-sectional view of a designating rod;
FIG. 8 is a schematic diagram illustrating details of a position detecting circuit;
FIG. 9 is a signal waveform diagram of various parts shown in FIG. 8;
FIG. 10 is a schematic diagram illustrating tuning circuits of the marker and the eraser as well as details of a writing instrument discriminating circuit;
FIG. 11 is a signal waveform diagram of various parts shown in FIG. 10;
FIG. 12 is a schematic diagram illustrating details of a data processing device;
FIG. 13 is a flowchart illustrating processing by a microprocessor of the data processing device;
FIG. 14 is a diagram illustrating a second embodiment of the present invention;
FIG. 15 is a detailed schematic diagram of tuning circuits of the marker and the eraser and the writing instrument discriminating circuit;
FIG. 16 is a signal waveform diagram of various parts shown in FIG. 15; and
FIG. 17 is a flowchart of processing by a control circuit of the writing instrument discriminating circuit.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a first embodiment of an electronic blackboard system in accordance with the present invention. The electronic blackboard system comprises the following major components: a blackboard body 1, a marker 2, an eraser 3, a designating rod 4, a position detecting circuit 5, a writing instrument discriminating circuit 6, a data processing device 7, an output unit 8, and a communication line 9.
The blackboard body 1 is arranged such that a casing 11 made of a non-magnetic metal is provided with an antenna coil 13 for transmission (hereafter referred to as the transmission coil), and an antenna coil 14 for reception (hereafter referred to as the reception coil). The tablet 12 is connected to the position detecting circuit 5, while the transmission coil 13 and the reception coil 14 are connected to the writing instrument discriminating circuit 6.
FIG. 2 is a top plan view illustrating a structure of the tablet 12, while FIG. 3 is a cross-sectional view taken along the line III--III in the direction of the arrows in FIG. 2. In the drawings, a plurality of magnetostrictive transmission medium elements 121 are disposed in the X- and Y-directions substantially in parallel with each other, respectively. Any material can be used as the magnetostrictive transmission medium elements 121, but a material having a large magnetostrictive effect, i.e., an amorphous alloy containing a large amount of iron, is particularly preferable so as to produce strong magnetostrictive vibratory waves. In addition, a material having such a small retaining force that it is difficult to be magnetized even if a magnet is brought adjacent thereto. As for the amorphous alloy, for instance, it is possible to use Fe 67 CO 18 B 14 Si 1 (atomic %), Fe 81 B 13 .5 Si 3 .5 C 2 (atomic %) and the like. Each of the magnetostrictive transmission medium elements 121 has an elongated configuration, its cross section being preferably shaped into the form of a thin rectangular strip or a circular rod. In the case of the thin rectangular strip, the width of several millimeters or thereabouts and the thickness of several microns to several dozens of microns or thereabouts facilitate produce and yield excellent characteristics. Since an amorphous alloy can be fabricated into a small thickness of 20 to 50 microns, this may be cut into the form of a thin strip or a rod. In this embodiment, magnetostrictive transmission medium elements each made of Fe 81 B 13 .5 Si 3 .5 C 2 (automic %) and having the width of 2 mm and the thickness of 0.02 mm are used.
Elongated tubular reinforcements 122 are made of a synthetic resin or the like and accommodate therein the magnetostrictive transmission medium elements 121, respectively.
An X-direction first coil 123 is disposed on end portions of the reinforcements 122 for the magnetostrictive transmission medium elements 121 arranged in the X-direction. This X-direction first coil 123 is twisted between the adjacent reinforcements 122 and is wound around each of the adjacent magnetostrictive transmission medium elements 121 in an alternately opposite direction. The arrangement is such that the direction of a magnetic flux produced in portions corresponding to the respective magnetostrictive transmission medium elements 121 when a current is allowed to flow through the coil 123 or the direction of a voltage produced in the aforementioned portions when a magnetic flux is applied to the coil 123 in one direction becomes opposite to that of an adjacent one. For this reason, the pulse noises and induced voltages from the outside which are generated when a pulse current is allowed to flow through the coil 123 offset each other between the adjacent portions of the coil 123 and thus become weak. Incidentally, although one turn is provided in the illustrated example in terms of the number of turns, two or more turns may be provided. This X-direction first coil 123 is designed to produce instantaneous fluctuations in the magnetic field and to produce magnetostrictive vibratory waves in the wound portions of the magnetostrictive transmission medium elements 121, one end of the coil 123 being connected to the position detecting circuit 5 and the other being grounded.
A-direction first coil is disposed on end portions of the reinforcements 122 for the magnetostrictive transmission medium elements 121 arranged in the Y-direction. This Y-direction first coil 124 is twisted between the adjacent reinforcements 122 and is wound around each of the adjacent magnetostrictive transmission medium elements 121 in an alternately opposite direction. One end of this Y-direction first coil 124 is connected to the position detecting circuit 5 and the other end is grounded in the same way as the coil 123. The operation of this Y-direction first coil is the same as that of the coil 123.
A pair of biasing magnetism generators 125, e.g., square magnets, are respectively designed to apply a bias magnetic field to the wound portion of the X-direction first coil 123 and the wound portion of the Y-direction first coil 124 in a direction parallel to the longitudinal direction thereof. The reason for thus applying a bias magnetic field is to enable production of large magnetostrictive vibratory waves with a small current and to designate the positin of occurrence of the magnetostrictive vibratory waves. In other words, since the electrical mechanical coupling coefficient (a coefficient indicating the efficiency of conversion from mechanical energy to electricl energy or vice versa) of the magnetostrictive transmission medium element 121 becomes maximum at the time of a bias magnetic field such as the one shown in FIG. 4, the magnetostrictive vibratory waves can be produced with a high degree of efficiency by applying such a magnetic bias to the wound portions of the X-direction first coil 123 and the Y-direction first coil 124.
Y-direction second coils 126 are disposed on the reinforcements 122 over a wide range of the magnetostrictive transmission medium elements 121 that are arranged in the X-direction. The coils 126 are wound around all of these magnetostrictive transmission medium elements 121 in the same direction (counterclockwise in this embodiment) and are connected in series in such a manner that the polarity of connection becomes opposite between the adjacent coils. Accordingly, the direction of a voltage and a current produced in each of the coils 126 when a unidirectional magnetic flux is applied to all the coils 126 or the direction of a magnetic flux produced in each of the coils 126 when a current is allowed to flow through all the coils 126 becomes opposite between the adjacent coils. Hence, the voltage induced from the outside and noises offset each other between the adjacent coils and consequently become weak.
As for the winding pitch of the coils 126, the coils 126 are wound such as to become gradually denser toward the side of the other opposite ends than the side of ends adjacent to the X-direction first coil 123, thereby compensating for the induced voltage from becoming small due to the attenuation of the magnetostrictive vibratory waves. Generally, in order to increase an induced electromotive force, the winding pitch should preferably be large. These X-direction second coils are designed to detect an induced voltage resulting from magnetostrictive vibratory waves propagating through the magnetostrictive transmission medium elements 121, one end thereof being connected to the position detecting circuit 5 and the other end being grounded. The wound area serves as a position detecting area.
In addition, Y-direction second coils 127 are disposed on the reinforcements over a wide range of the magnetostrictive transmission medium elements that are arranged in the Y-direction. The coils 127 are wound around all of these magnetostrictive transmission medium elements 121 in the same direction (counterclockwise in this embodiment) and are connected in series in such a manner that the polarity of connection becomes opposite between the adjacent coils. In addition, as for the winding pitch of the coils 127, the coils 127 are wound such as to become gradually denser toward the side of the other opposite ends than the side of ends adjacent to the Y-direction first coil 124, one end thereof being connected to the position detecting circuit 5 and the other being grounded in the same way as the coils 126. Incidentally, the operation of the coils 127 is similar to that of the coils 126.
The X-direction position detecting section comprising the magnetostrictive transmission medium elements 121 in the X-direction, the reinforcements 122 thereof, the X-direction first coil 123, and the X-direction second coils 126 on the one hand, and the Y-direction position detecting section comprising the Y-direction magnetostrictive transmission medium elements 121, the reinforcements 122 thereof, the Y-directions first coil 124, and the Y-direction second coils 127 on the other are superposed on each other such as to be perpendicular to each other and are accommodated substantially in the center of the casing 11. In addition, the biasing square magnets 125 are accommodated in and fixed to the casing 11 in such a manner as to oppose the end portions of the magnetostrictive transmission medium elements 121, but may be arranged in parallel such as to be disposed above, below, or laterally of the magnetostrictive transmission medium elements 121.
A portion of the casing 11 corresponding to the tablet 12 is formed of aluminum- or austenite-based stainless steel or the like whose surface is enamel finished, and is arranged to constitute the writing surface 15 which can be used repeatedly.
The transmission coil 13 and the reception coil 14 are repectively arranged such that conductors provided with insulation coating are arranged on the surface of the casing 11 around the writing surface 15, i.e., the coordinates inputting range. Incidentally, although both of the transmission coil 13 and the reception coil 14 are shown as being one-turn coils in the drawings, but actually have several turns.
FIG. 5 shows a detailed structure of the marker 2. This marker 2 comprises: a pen shaft 21 constituted by two portions 21a and 21b which are formed of a non-metallic material such as a synthetic resin and are coupled with each other by being screwed in; a pen body 22 such as a commercially available black felt pen; and annular magnet 23 for designating a position; annular magnets 24a, 24b; a tuning circuit 25 having a switch 251, a coil 252 with a core, a capacitor 253, and a variable capacitor 254; and a cap 26 for the pen body 22.
The pen body 22 is accommodated in such a manner as to be slightly slidable between a stopper 21a' provided in the portion 21a inside the pen shaft 21 and the switch 251 accommodated in the portion 21b. In addition, the magnets 24a, 24b are designed to extend the magnetic flux of the magnet 23 in the axial direction of the pen body 22 and is arranged such that the same position as that of the tip of the pen body 22 can be designated even in a state in which the marker 2 is slightly inclined.
As also shown in FIG. 10, the tuning circuit 25 is arranged such that one end of the coil 252 is connected to ends of the capacitor 253 and the variable capacitor 254 via the switch 251, while the other end of the coil 252 is connected to the other ends of the capacitor 253 and the variable capacitor 254. When the tip of the pen body 22 is contacting nothing, the switch 251 is in a non-operative state, and the one end of the coil 252 is not connected to the one end of the variable capacitor 254. Meanwhile, if the pen shaft 21 is held with fingers or the like and the tip of the pen body 22 is pressed against the writing surface 15 or the like so as to be pressed into the pen shaft 21, the switch 251 is pressed by a rear end thereof and assumes an operative state, and the one end of the coil 252 is connected to the ends of the capacitor 253 and the variable capacitor 254. Numerical values of the coil 252, the capacitor 253, and the variable capacitor 254 are set to those values that constitute a known resonance circuit which resonates at a predetermined frequency f1, e.g., 280 kHz.
It is assumed that there are two other types of marker (not shown) that are similar to the above-described marker 2, excluding the fact that, in the case of one marker, the color of the ink of the pen body 22 is red and the resonant frequency of the turning circuit 25 is a predetermined frequency f2, e.g., 290 kHz, while, in the case of the other marker, the color of the ink of the pen body 22 is green and the resonant frequency of the tuning circuit 25 is a predetermined frequency f3, e.g., 300 kHz.
FIG. 6 illustrates a detailed structure of the eraser 3. The eraser 3 comprises: a case 31 made of a non-metallic material such as a synthetic resin; a tuning circuit 32 having switches 321, 322, a coil 323 with a core, a capacitor 324, and a variable capacitor 325 that are accommodated in the interior 31a of the case 31; a movable plate 33 having a configuration corresponding to a bottom surface of the case 31; springs 34 inserted between the movable plate 33 and the case 31; a stopper 35 for engaging with an engaging portion 31b of the interior 31a and adapted to restrict the position of the movable plate 33 with respect to the case 31; a pair of annular magnets 36 for designating a position respectively provided at opposite ends of the movable plate 33; and an erasing member 37, such as felt, provided on an outer surface of the movable plate 33. The movable plate 33 is held so as to move slightly with respect to the case 31 in such a manner that either one of the switches 321 and 322 can be moved or both of them can be moved simultaneously.
As is also shown in FIG. 10, the tuning circuit 32 is arranged as follows: One end of the coil 323 is connected to ends of the capacitor 324 and the variable capacitor 325 via the switches 321 and 322, while the other end of the coil 323 is connected to the other ends of the capacitor 324 and the variable capacitor 325. When the erasing member 37 is contacting nothing, the switches 321 and 322 are in a non-operative state, and the one end of the coil 323 is not connected to the ends of the capacitor 324 and the variable capacitor 324. Meanwhile, if the case 31 is held with fingers or the like and the erasing member 37 is pressed against the writing surface 15 or the like so as to press the movable plate 33 into the case 31, either one of the switches 321 and 322 or both of them are pressed by the movable plate 33 and assume an operative state, with the result that the one end of the coil 323 is connected to the other ends of the capacitor 324 and the variable capacitor 325. Incidentally, numerical values of the coil 323, the capacitor 324, and the variable capacitor 325 are set to those values that constitute a known resonance circuit which resonates at a known frequency f4, e.g., 310 kHz.
FIG. 7 shows a detailed structure of the designating rod 4. The designating rod 4 is made of a synthetic resin, wood, metal or the like and comprises a body 41 having at a tip portion thereof a recess 41a for accommodating a magnet, a position designating magnet 42 embedded in the recess 41a, and a cap 43 for covering the recess 41a. Incidentally, the body 41 may be formed such as to be capable of expansion and contraction.
FIG. 8 shows a detailed configuration of the position detecting circuit 5. The position detecting circuit 5 comprises the following maim components: a pulse signal generator 501, a 1/2 divider 502, an X-direction pulse current generator 503; a Y-direction pulse current generator 504; a flip-flop 505; a counter 506; an analog multiplexer 507; a control circuit 508; an amplifier 509; a comparator 510; an AND circuit 511; and a clock generator 512.
FIG. 9 shows the waveforms of signals in the respective components shown in FIG. 8, and the operation will be described hereafter together with the arrangement of the respective components shown in FIG. 8.
When the power is turned on, the pulse signal generator 501 generates a pulse signal (a) having a period equivalent to a time during which magnetostrictive vibratory waves propagate from one end of the magnetostrictive transmission medium element 121, are reflected at the end thereof, and then return to the one end thereof. The pulse signal (a) is divided into halves by the 1/2 divider 502 so as to be converted into an X/Y changeover signal (a) and is supplied to the analog multiplexer 507 and the control circuit 508. At the same time, this signal is supplied as it is to the X-direction pulse current generator 503, the Y-direction pulse current generator 504, the flip-flop 505, and the counter 506.
The X/Y changeover signal (b) is designed to control the changeover for connection with the analog multiplexer 507 and supply information on the direction of position detection to the control circuit 508. When the level of this X/Y changeover signal (b) is high, an X-terminal and a Z-terminal are connected to each other, and the data thus obtained is used as the coordinate data in the X-direction. Meanwhile, when the level of the X/Y changeover signal (b) is low, a Y-terminal and a Z-terminal are connected to each other, and the data thus obtained is used as the coordinate data in the Y-direction.
The X-direction pulse current generator 503 and the Y-direction pulse current generator 504, upon receiving the pulse signal (a), applies a pulse current (c) to the X-direction first coil 123 and the Y-direction first coil 124, respectively, thereby causing magnetostrictive vibratory waves to be produced at ends of the magnetostrictive transmission medium elements 121 in the X- and Y-directions. In addition, the flip-flop 505 and the counter 506 are reset by the pulse signal (a), and the counter 506 starts counting the clock pulses of the clock generator 512 supplied thereto via the AND circuit 511.
The magnetostrictive vibratory waves produced at the ends of the magnetostrictive transmission medium elements 121 in the X- and Y- directions propagate toward the respective other ends at a predetermined speed (approx. 5,000 m/sec.). During this propagation, the magnetostrictive vibratory waves are converted from mechanical energy into electrical energy in accordance with the magnitude of the electrical mechanical coupling coefficient at various positions of the respective magnetostrictive transmission medium elements 121. Thus, induced voltages (d) and (e) are respectively produced in the X-direction second coils 126 and the Y-direction second coils 127. The induced voltages (d) and (e) are alternately output by the analog multiplexer 507 in response to the level of the X/Y changeover signal (b) and are thus converted into a signal (f), which is amplified by the amplifier 509 so as to be converted into a signal (g), which in turn is supplied to the comparator 510 where the signal is compared with a predetermined threshold voltage E TH .
At this juncture, it is assumed that a writing instrument such as the marker 2 or the eraser 3 or the designating rod 4 is being used on the writing surface 15 of the blackboard body, and that the magnet 23, 36 or 42 is applying magnetism to the magnetostrictive transmission medium elements 121 in the X- and Y-directions to such an extent as to increase the electrical/mechanical coupling coefficient. Then, a voltage above the threshold voltage E TH is produced in the signal (g) in correspondence with the time when the magnetostrictive vibratory waves reach the portion of the magnetostrictive transmission medium element 121 in the X- or Y-direction where magnetism is being applied.
Upon detecting a voltage above the threshold voltage E TH , the comparator 510 outputs a high-level signal to set the flip-flop 505. Subsequently, the AND circuit 511 is closed by an output Q of the flip-flop 505, and the counting by the counter 5069 is thereby stopped. The count of the counter 506 represents the time which has elapsed after the pulse signal (a) was output. Furthermore, this time corresponds to a distance from the portion of the magnetostrictive transmission medium element 121 in the X- or Y-direction where the first coil is wound to the portion thereof where the magnetism is applied, i.e., coordinate data.
Upon receiving the output Q, the control circuit 508 reads and temporarily stores the count of the counter 506 and the level of the X/Y changeover signal (b). As described before, since the X/Y changover signal is changed over each time the pulse signal (a) is generated, the coordinate data in the X- and Y-directions are obtained alternately. These data are supplied consecutively to the data processing device 7 at predetermined timings.
In addition, at this time, in a case where a writing instrument such as the marker 2 or the eraser 3 or a designating rod 4 is not sufficiently close to the writing surface 15 and its magnet 23, 36, or 42 is not applying a sufficient magnetic bias to the magnetostrictive transmission medium elements 121 of the tablet 12, an induced voltage above the threshold voltage E TH is not produced in the signal (g). Accordingly, the coordinate data is not obtained by the control circuit 508 without the flip-flop 505 being set by the comparator 510.
Although, in the above-described embodiment, the X-direction first coil 123 and the Y-direction first coil 124 are used to generate magnetostrictive vibratory waves, and the X-direction second coils 126 and the Y-direction second coils 127 are used to detect the magnetostrictive vibratory waves, a reverse arrangement may be adopted. In that case, the magnetostrictive vibratory waves are produced immediately below the magnet 23, 36 or 42 of a writing instrument such as the marker 2 or the eraser 3 or the designating rod 4, and induced voltages are produced in the first coils 123, 124.
FIG. 10 shows a detailed configuration of the writing instrument discrimination circuit 6 which constitutes a circuit for discriminating a writing instrument being used, i.e., one of the marker 2 and the eraser 3, as well as the tuning circuit of the marker 2 and the eraser 3. As shown in FIG. 10, the writing instrument discrimination circuit 6 comprises the following main components: a reference signal generating circuit 601; an alternating signal generating circuit 602; transmission and reception changeover circuits 603, 604; a drive circuit 605; capacitors 606, 607; an amplifier 608; phase detectors (PSD) 609, 610; low-pass filters (LPF) 611, ,612; comparators 613, 614, 615, 616; pulse-width detectors 617, 618, 619, 620; an OR circuit 621; a flip-flop 622; a latch circuit 623; and a mono-multi circuit 624.
Incidentally, it is assumed that portions indicated by *, * in FIG. 10 are connected.
FIG. 11 illustrates signal waveforms in the respective components shown in FIG. 10, and a description will be given hereafter of the arrangement and operation of each of the components shown in FIG. 10.
The reference signal generating circuit 601 generates the following signals: a transmission/reception changeover signal TR of a predetermined frequency fk, e.g., 9,375 Hz; a changeover signal A in which the transmission/reception a changeover signal TR is divided into two equal parts; a changeover signal B in which the transmission/reception changeover signal TR is divided into four equal parts; a control signal TRQ in which the phase of the tansmission/reception changeover signal TR is delayed 90 degrees (1/4 wavelength); a control signal TRD in which the phase of the transmission/reception changeover signal TR is delayed 22.5 degrees (1/16 wavelength); and a control signal MUTE in which the period of the high (H) level of the transmission/reception changeover signal TR is extended by a 1/8 wavelength.
The transmission/reception changeover signal RT is supplied to the transmission/reception changeover circuit 603 and the flip-flop 622; the changeover signals A, B are supplied to the alternating signal generating circuit 602 and the latch circuit 623; the control signal TRQ is suplied to the pulse-width detectors 617-620; the control signal TRD is supplied to a clock terminal of the flip-flop 622; and the control signal MUTE is supplied to the transmission/reception changeover circuit 604.
The alternating signal generating circuit 602 has rectangular wave signal generators respectively producing rectangular wave signals of frequencies f1, f2, f3, f4. In addition, as the levels of the changeover signals A, B change consecutively and repeatedly in the order of "L (low level), L", "H, L", "L, H", and "H, H" for each predetermined time 2T (=1/fk), the alternating signal generating circuit 602 correspondingly generates a signal FI for consecutively repeating the rectangular wave signals of the frequencies f1, f2, f3, f4 as well as a signal FIQ for consecutively repeating a signal in which the phases of the rectangular wave signals of the frequencies f1, f2, f3, f4 are delayed 90 degrees (1/4 wavelength), for each predetermined time 2T in a manner similar to that described above.
The aforementioned signal F1 is supplied to the phase detector 609, and is converted into a sinusoidal signal by a low-pass filter (not shown) and supplied to one input terminal of the transmission/reception changeover circuit 603. Meanwhile, the signal FIQ, having a phase displaced by 90° from the reference phase of signal FI, is supplied to the phase detector 610.
The other input terminal of the transmission/reception changeover circuit 603 is grounded. Since the one input terminal is selected when the transmission/reception changeover signal TR is of high level and the other imput terminal is selected when it is of low level, a transmission signal C, which causes sinusoidal signals of the frequencies f1-f4 to be issued consecutively only for the time duration T at intervals of time 2T or causes the same not to be issued, is output by the transmission/reception changeover circuit 603.
The signal C is supplied to a drive circuit 605 and further to the transmission coil 13 via the capacitor 606. However, since the capacitor 606 and the transmission coil 13 constitute a serial resonance circuit having resonance frequencies centering on the frequencies f1-f4, the serial resonance circuit resonates, and radiowaves of the frequencies f1-f4 are consecutively transmitted by the transmission coil 13 for the time duration T at intervals of time 2T.
At this juncture, if a writing instrument, such as the marker 2, is used on the writing surface 15 of the blackboard body 1, and if the writing instrument is held in such a manner that an angle formed between the pen shaft 21 and the writing surface is kept within 90°-45° or thereabouts with the tip of the pen body 22 contacting the writing surface 15 and with the switch 251 kept in an operative state, the component of the frequency f1 among the aforementioned radiowaves excites the coil 252 of the marker 2, which in turn causes an induced voltage synchronized with the component of the frequency f1 of the signal C to be produced in the tuning circuit 25 thereof (actually, however, the coil 252 is excited by the components of the other frequencies f2-f4 among the radiowaves, but since the frequencies are slightly different, their amplitude is small).
Subsequently, when the signal C is not generated, i.e., during the period of reception, the transmission coil 13 is grounded, so that the alternating signal in the above-described serial resonance circuit is speedily set to 0, and its radiowaves disappear immediately. However, the aforementioned induced voltage gradually attenuates in accordance with the loss in the tuning circuit 25.
On the other hand, the current flowing through the tuning circuit 25 on the basis of the induced voltage causes the coil 252 to transmit radiowaves of the frequency fl. These radiowaves excite the transmission coil 14, causes a parallel resonance circuit, comprising the reception coil 14 and the capacitor 607 connected parallel thereto and having resonance frequencies cantering on the frequencies fl-f4, to resonate, and causes the parallel resonance circuit to produce an induced voltage of the frequency f1 (actually, however, the reception coil 14 is excited by radiowaves transmitted by the transmission coil 13, but since the reception coil 14 is grounded during this period, as will be described later, no induced voltage is generated). The induced voltage is transmitted to and amplified by the amplifier 608 and, and is further transmitted to the transmission/reception changeover circuit 604.
The transmission/reception changeover circuit 604 is arranged such as to change over the output of the amplifier 608 to the phase detectors 609, 610 or to ground on the basis of the control signal MUTE. When the control signal MUTE is of low level, the output of the amplifier 608 is connected to the phase detectors 609, 610, while, when the signal is of high level, the output is connected to ground. Accordingly, a signal D, which is provided with the induced voltage of the frequency f1 based on the frequency component f1 of the signal C as well as an induced voltage of the frequency f1 based on the frequency components f2-f4 of the signal C, is obtained in the output of the transmission/reception changeover circuit 604.
Although the signal D is transmitted to the phase detectors 609, 610, since the above-described signal F1 has already been supplied to the phase detector 609 as a detection signal. Hence, among the induced voltages contained in the signal D, both the frequencies and phases of portions corresponding to the component of the frequency f1 in the signal FI agree with each other. However, the frequencies of the portions corresponding to the components of the other frequencies f2-f4 do not agree with each other. In addition, the aforementioned signal FIQ has already been supplied to the phase detector 610 as a detection signal, and, among the induced voltages contained in the signal D, with respect to portions corresponding to the component of the frequency f1 in the signal FIQ, the frequencies agree with each other, but the phases do not, while the frequencies do not coincide with respect to portions corresponding to the components of the other frequencies f2-f4.
Accordingly, the phase detector 609 outputs a signal which has only a positive-side signal component with respect to that portion of the induced voltages contained in the signal D that corresponds to the component of the frequency F1 in the signal FI, and which has a signal components on the positive and negative sides with respect to portion corresponding to the components of the other frequencies f1-f4. Meanwhile, the phase detector 610 outputs a signal which has a signal component on the positive and negative sides with respect to those portions of the induced voltages (contained in the signal D) that correspond to the components of the frequencies fl-f4 in the signal FI.
The output signal of the phase detector 609 is supplied to the low-pass filter 611 having a sufficiently low cut-off frequency and is converted into a signal E which, with respect to a portion corresponding to the component of the frequency f1 in the signal FI, has a positve DC voltage provided with a predetermined time span and a voltage, and, with respect to portions corresponding to the components of the other frequencies f2-f4, has an AC voltage corresponding to a difference in the frequency between the frequencies f2-4 and the frequency f1, and is supplied to the comparators 613, 614. In addition, the output signal of the phase detector 610 is supplied to the low-pass filter similarly having a sufficiently low cut-off frequency, where the signal is converted into a signal F having an AC voltage corresponding to a difference in the frequency or phase between the frequencies f1-f4 and the frequency f1 with respect to portions corresponding to the components of the frequencies fl-f4 in the signal FI and is then supplied to the comparators 615, 616.
Using 0.5 V or thereabouts as a threshold voltage, the comparators 613, 615 output a low-level voltage when the voltage of the input signal is the threshold voltage or above and a high-level voltage when it is below the threshold voltage. Meanwhile, using -0.5 V or thereabouts as a threshold voltage, the comparators 614, 616 output a low-level voltage when the voltage of the input signal is low and high-level voltage when it is the threshold voltage or above.
Accordingly, the signals G, H, I, J are respectively obtained in the outputs of the comparator 613-616, and are respectively supplied to the pulse-width detectors 617 -620.
The pulse-width detectors 617-620 output detection pulses when they detect pulses of a predetermined time span, e.g. T/2 of more, in their input signals. However, in the case of the above-described signals G-J, the pulse-width detector 617 detects a positive DC voltage corresponding to the component of the frequency f1 in the signal FI and generates a pulse. That signal K is supplied to the flip-flop 622 via the OR circuit 621.
The reason why two phase detectors and two low-pass filters are used, four comparators and four pulse-width detectors, and a sum of the outputs of the pulse-width detectors in adapted to be obtained by the OR circuit is to ensure that, even if the frequency of the tuning circuit slightly deviates due to a change with time or the like, the radiowaves reflected by the tuning circuit can be detected.
The flip-flop 622 generates a signal L from the signal K, control signals TRD and TR, and supply them to a data input terminal and a clock termianl of the latch circuit 623 and the mono/multi circuit 624.
The latch circuit 623 latches the signals input to the respective data terminals at the rising of the signal L, i.e., the changeover signals A, B and the signal L itself. The latched signal L is supplied to the data processing device 7 as a signal ml which indicated with high level a state in which a writing instrument, i.e., the marker 2, is designating the coordinates to be input (this signal ml is hereafter referred to as the "pen-down signal").
In addition, as described above, the levels of the changeover signals A, B indicate that the frequency of the transmission signal FI at that point of time is any of fl, f2, f3, f4, and the latched signals A, B are supplied to the data processing device 7 as 2-bit discrimination information m2, m3 (here "L, L") which indicate the tuning frequency of the tuning circuit of the writing instrument being used is any of fl-f4, i.e., whether the writing instrument being used is the marker 2 or the eraser 3. Incidentally, the pen-down signal ml and the writing instrument discrimination information m2, m3 will be collectively called a writing instrument discrimination signal M.
Upon receiving a rise of the signal L, the mono/multi circuit 624 generates a pulse signal of a time span which is slightly longer than a time 8T and speedily clears the latch circuit 623 when the signal L is not output in the next cycle, i.e., when the writing instrument being used (in this case, the switch 251 of the marker 2) is off (i.e., pen-up), thereby stoppin the supply of the writing instrument discrimination signal M.
In addition, when the eraser 3 is used on the writing surface 15 of the blackboard body 1, i.e., a part or all of the erase member 37 is pressed against the writing surface 15, and when either or both of the switches 321, 322 of the tuning circuit 32 thereof become operative, radiowaves corresponding to the frequency f4 are reflected from the tuning circuit 32. Therefore, the writing instrument discrimination circuit 6 discriminates this in the same manner as described above, and supplies the pen-down signal ml and the writing instrument discrimination information m2, m3 (here "H, H") to the data processing device 7.
Furthermore, when the designating rod 4 is being used on the writing surface 15 of the blackboard body 1, or the marker 2 or the eraser 3 is not contacting the writing surface 15, i.e., when the switch 251, 321, or 322 is used in the off state, no radiowaves are reflected. Accordingly, the writing instrument discrimination circuit 6 outputs the low-level pen-down signal m1 which means that there is no writing instrument.
On the other hand, as described above, the position detecting circuit 5 detects a position from the time when a magnetic bias caused by the magnet 23 of the marker 2, the magnet 36 of the eraser 3, or the magnet 42 of the designating rod 4 has reached a range in which the coordinates of the tablet 12 can be detected, and the position detecting circuit 5 continues to supply those coordinates to the data processing device 7.
FIG. 12 illustrates a configuration of the data processing device 7. The data processing device 7 comprises the following major components: a microprocessor 71, an image memory 72, an overlay memory 73, a display controller 74, a video processor 75, a printer interface 76, and a communication interface 77.
In addition, FIG. 13 shows a schematic flowchart of the microprocessor 71, and the operation of the data processing device 7 will be described below.
First, upon receiving the coordinate data from the position detecting circuit 5, the microprocessor 71 discriminates whether or not the discrimination signal M is present (actually, whether the pen-down signal m1 is of high level or low level).
If the discrimination signal M is present, discrimination is further conducted on the basis of the discrimination information m2, m3 thereof as to whether the data has been given by the marker 2 or by the eraser 3. If the data is that given by the marker 2, bit "1" is written in the corresponding coordinates of the image memory 72. Strictly speaking, the image memory 72 is constituted by frame memories corresponding to the colors (black, red, green) of the respective inks of the marker 2, and bit "1" is written in the frame memory corresponding to the color discriminated by the discrimination information m2, m3 (for instance, the color in the above-described case is black since m2, m3="L, L"). Meanwhile, if the data is that given by the eraser 3, that data is recognized as set coordinates in a predetermined range to be erased by the eraser 3, and bit "0" is written in a range predetermined by the coordinates in the image memory 72, thereby erasing the video date.
On the other hand, if the discrimination signal M is not present, a pattern of a cursor, such as an arrow ↑, is generated by a character generator (not shown), and this is written in the corresponding coordinates of the overlay memory 73. Incidentally, the content of the image memory 72, once written, is arranged to be held unless other data is written therein. However, the content of the overlay memory 73 is arranged to be lost unless data is rewritten within a predetermined time (normally several milliseconds). In addition, if the coordinate data supplied from the position detecting circuit 5 undergoes change, the position of the cursor also changes correspondingly.
The contents of the image memory 72 and the overlay memory 73 are read simultaneously, are then sent to the video processor 75 where they are converted into a video signal, which is further supplied to the display device 81, such as a color CRT, so as to be displayed.
The writing and reading of data with respect to the memories 72, 73 are controlled by the display controller 74.
Thus, when the marker 2 or the eraser 3 is used on the writing surface 15, the content of the image memory 72 is rewritten in correspondence with the image at that time. Alternately, if the designating rod 4 is used or the marker 2 or the eraser 3 is used without being brought into contact with the writing surface 15, the cursor is written in the overlay memory 73 in correspondence with the position on the image at that time. Accordingly, the image formed by the writing instrument can be displayed in dots on the screen of the display device 81, and, at the same time, a desired portion of the image can be designated by the cursor.
In addition, an arrangement can be provided such that it is possible to display an expanded image of a particular area of the writing surface 15 on the screen of the display device 81 and to move the image of the particular area in correspondence with the movement of the designating rod 4 on the screen.
Furthermore, at that time, if the electronic blackboard system is connected with another similar system via the communication interface 77 and the communication line 9 and transmission and reception of data is being carried out, the above-described coordinate data and the discrimination signal M are transmitted as they are, with the result that the same picture and cursor as those described above can be displayed on the display device of the other electronic blackboard system.
Incidentally, when a hard copy of the image is to be obtained, since only the content of the image memory 72 is sent to the printer 82 via the printer interface 76, so that the cursor is not recorded in the hard copy.
In the above-described embodiment, the transmission coil 13 and the reception coil 14 are disposed such as to be spaced apart from each other to such an extent that they do not affect each other so much. However, their positions may be reversed, and the coils 13 and 14 may be arranged perpendicularly to the board surface of the blackboard body 1. In addition, to effect more stable transmission and reception of radiowaves, the ground of the transmission/reception changeover circuits 603, 604 may be connected to the writing surface 15 made of a metal.
Moreover, although, in the above-described embodiment, radiowaves are used as a wireless signal, it is also possible to use known ultrsonic waves, infrared rays, or the like. In such a case, the writing instrument may be provided with a transmitter, and the blackboard body may be provided with a receiver.
FIGS. 14 to 17 illustrate a second embodiment of the present invention. As shown in FIG. 14, this embodiment is a case where three markers 2a to 2c are used instead of the designating rod 4. In these drawings the arrangement of this embodiment is similar to that of the foregoing embodiment except those described below. The markers 2a to 2c basically have the same constructions that shown in FIG. 5, but the marker 2a is black in terms of the color of the ink of the pen body 22, and the tuning frequency f1 of the tuning circuit 25 is set to, for instance, 280 kHz. On the other hand, the markers 2b and 2c are, for instance, red and green in terms of the color of the ink of the pen body 22, and the tuning frequencies of the tuning circuits 25 are respectively set to predetermined frequencies f2 and f3, e.g. 290 kHz and 300 kHz.
FIG. 15 shows detailed configurations of the tuning circuits of the markers 2a to 2c and the eraser 3 as well as a writing instrument discrimination circuit 6'. The writing instrument discrimination circuit 6' comprises the following major components: a control circuit 701; a timing circuit 702; an inverter 703; analog switches 704, 705; a drive circuit 706; capacitors 707, 708; an amplifier 709; a phase detector (PSD) 710; a low-pass filter (LPF) 711; and a pulse detector 712.
FIG. 16 is a signal waveform diagram in the respective parts shown in FIG. 15. A detailed description will now be given the arrangements of the respective parts shown in FIG. 15 and their operation.
The control circuit 701 is constituted by a known microprocessor or the like and supplies a timing signal for starting the operation to the timing circuit 702 in accordance with the flowchart shown in FIG. 17. The control circuit 701 receives an output signal from the pluse detector 712, discriminates the type of the writing instrument being used, i.e., whether the markers 2a to 2c or the eraser 3 is being used, in accordance with the frequency information transmitted from the timing circuit 702, and supplies the same to a data processing device 7'.
The timing circuit 702 comprises rectangular wave signal generators 702a, 702b, 702c, 702d, 702e for generating rectangular wave signals of frequencies f1, f2, f3, f4, fk, respectively, as well as a dividing counter 702f and a multiplexer 702g. The rectangular wave signals of the frequencies f1 to f4 are respectively input to the input terminals of the multiplexer 702g, while the rectangular wave signal of the frequency fk is divided into two equal parts and four equal parts by the dividing counter 702f, signals thereof being input to the control terminals of the multiplexer 702g. The multiplexer 702g outputs a signal A which consecutively repeats rectangular wave signals of the frequencies f1, f2, f3, f4 at intervals of a predetermined time duration 2T (=1/fk). In additio the rectangular wave signal of the predetermined frequency fk is output as a transmission/reception changeover signal B, while the signals obtained by dividing the rectangular wave signal of the frequency fk into two equal parts and four equal parts are output as 2-bit transmitted frequency information C1 and C2 which indicate which of f1 to f4 is being used as the frequency of the signal A at that time.
The signal A is supplied to the position detector 710 and is converted into a sinusoidal signal by means of a low-pass filter (not shown), which is then supplied to one input terminal of the analog switch 704. Meanwhile, the transmission/reception changeover signal B is supplied to the control terminal of the analog switch 704 and also to the inverter 703. The transmitted frequency information C1, C2 is supplied to the control circuit 701.
The other input terminal of the analog switch 704 is grounded. The analog switch 704 selects the one input terminal when the transmission/reception changeover signal B is of high (H) level and selects the other input terminal when the signal is of low (L) level. Therefore, the analog switch 704 outputs a signal D which sinusoidal signals of the frequencies f1-f4 are consecutively supplied for only the time duration T or not supplied at intervals of time 2T.
The signal D is supplied to the drive circuit 706 where the signal is converted into an equilibrium signal, which is further sent to the antenna coil 13. However, since the capacitor 707 and the antenna coil 13 constitutes a serial resonance circuit having resonance frequencies centering on the frequencies f1-f4, radiowaves ae consecutively transmitted from the antenna coil 13 for only the time duration T at intervals of time 2T.
At that juncture, if a marker such as 2a is used on the writing surface 15 of the blackboard body 1, i.e., if the marker 2 is held in such a manner that an angle formed between the pen shaft 21 and the writing surface is kept within 90°-45° or thereabouts with the tip of the pen body 22 contacting the writing surface 15 and with the switch 251 kept in an operative state, the component of the frequency f1 among the aforementioned radiowaves excites the coil 252 of the marker 2a which in turn causes an induced voltage synchronized with the component of the frequency f1 of the signal C to be produced in the tuning circuit 25 thereof (actually, however, the coil 252 is excited by the components of the other frequencies f2-f4 among the radiowaves, but since the frequencies are slightly different, their amplitude is small).
Subsequently, when the signal D is not generated, i.e., during the period of reception, the antenna coil 13 is grounded, so that the radiowaves disappear immediately. However, the aforementioned induced voltage E gradually attenuates in accordance with the loss in the tuning circuit 25.
On the other hand, the current flowing through the tuning circuit 25 on the basis of the induced voltage E causes the coil 252 to transmit radiowaves of the frequency f1. These radiowaves excite the antenna coil 14, causes a parallel resonance circuit comprising the antenna coil 14 and the capacitor 708 connected thereto to produce an induced voltage of the frequency f1 (actually, however, the antenna coil 14 is excited by radiowaves transmitted by the antenna coil 13, but since the antenna coil 14 is grounded during this period, as will be described later, no induced voltage is generated). The induced voltage is transmitted to and amplified by the amplifier 709, and is further transmitted to the analog switch 705.
The analog switch 705 is designed to change over the output of the amplifier 709 to the phase detector 710 or ground on the basis of an inversion signal B' of the transmission/reception changeover signal B input to the control terminal thereof via the inverter 703. Since the output of the amplifier 709 is connected to the phase detector 710 when the inversion signal B' is of the high level and to ground when it is of low level. Accordingly, a signal F which is provided with an induced voltage of the frequency f1 based on the frequency component f1 in the signal d as well as induced voltages of the frequency f1 based on the frequencies components f2 to f4 in the signal D is obtained as the output of the analog switch 705.
The signal F is supplied to the phase detector 710, but the signal A has already been input to the phase detector 710 as a detection signal. Accordingly, among the induced voltages contained in the signal F, the frequencies and phases of those portions corresponding to the component of the frequency f1 in the signal A agree with each other, but the frequencies and phases of those portions correspondings to the components of the other frequencies f2 to f4 do not agree with each other.
Therefore, among the induced voltages contained in the signal F, a signal F is output from the phase detector 710, and the signal F has a voltage component folded back to the positive side with respect to the portion corresponding to the component of the frequency f1 in the signal A and has a voltage components on the positive and negative sides with respect to portions corresponding to the components of the other frequencies f2 to f4.
The signal G is supplied to a low-pass filter 711 having a sufficiently low cut-off frequency. This low-pass filter 711 converts the signal G into a signal H. The signal H has a DC component provided with a predetermined time span and a predetermined voltage with respect to the portion corresponding to the component of the frequency f1 in the signal A, and also has an AC waveform corresponding to a frequency representing a difference between the frequencies f2-f4 and the frequency f1 with respect to the portion corresponding to the component of the other frequencies f2-f4. Subsequently, this signal H is supplied to the pulse detector 712.
The pulse detector 712 is constituted by a SChmitt trigger circuit, a pulse-width detection circuit or the like and is arranged such that, when it detects a pulse of a predetermined width such as T/2 or above in an input signal thereof, the pulse detector 712 supplies a pulse signal to the control circuit 701. In this case, a DC component of the signal H corresponding to the component of the frequency f1 in the signal A is detected to generate a pulse signal, and a signal I thereof is supplied to the control circuit 701.
Upon receiving the signal I, on the basis of the transmitted frequency information C1, C2 at that point of time, or "L, L" in this case, the control circuit 701 discriminates the writing instrument being used, i.e., the marker 2, and supplies this information to the date processing device 7'.
Meanwhile, regardless of the presence or absence of the discrimination information, the position detection circuit. 5 detects a position, starting from the time when a magnetic bias caused by the magnet 23, 24a, or 24b of the marker 2a reaches a detectable range of the coordinates of the tablet 12, and continues to send the coordinates to the data processing device 7'.
The data processing device 7' normally stores the coordinates output from the position detection circuit 5 in a buffer or the like as temporary values, but recognizes the coordinates when the discrimination information of the marker 2ais received, as the image data provided by the marker 2a, i.e., as the black image data, and then stores the same in an image memory or the like (not shown).
In addition, when the marker 2b or 2c is set in a usable state on the writing surface 15 of the blackboard body 1, the writing instrument discrimination circuit 6' discriminates the same in a manner similar to that described above, and sends the discrimination information thereof, i.e., the discrimination information on the marker 2b or 2c to the data processing device 7'. The data processing device 7', in a manner similar to that described above, recognizes the coordinates obtained at that time as the image data provided by the marker 2b or 2c, i.e., as the red or green image data, and stores the same in an image memory.
If the eraser 3 is used on the writing surface 15 of the blackboard body 1, i.e., if a part or all of the erasing member 37 is pressed against the writing surface 15 and either one or both of the switches 321, 322 of the tuning circuits thereof are set in an operative state, discriminates the same in a manner similar to that described above, and supplies the discrimination information, i.e., the discrimination information on the eraser 3, to the data processing device 7'. The data processing device 7' recognizes the coordinates obtained at that time as the set coordinates of the predetermined region to be erased by the eraser 3, and erases the image data in the predetermined range determined by the coordinates stored in the image memory.
Thus, the image data obtained in the image memory of the data processing device 7' is displayed on the color display (not shown) or output by the the output device 8, such as a color printer, as a hard copy, as necessary. Furthermore, the image data may be transmitted to another data processing device via a public telephone line, a data line or the like in the same way as the foregoing embodiment.
It goes without saying that, if the marker 2a-2c or the eraser 3 is merely brought close to the writing surface 15 of the blackboard apparatus 1 and unless the switch thereof is made operative, no pulse signal is issued from the pulse detector 712, so that the control circuit 701 does not output the discrimination information thereof. | A determination is made as to which one of plural objects is proximate a region having a coil therein. Each object includes a tuned circuit having a different resonant frequency. AC energy at the different resonant frequencies is supplied to the coil. The tuned circuit on the particular object in the region having substantially the same resonant frequency as the AC energy supplied to the coil causes a change in the current flowing in the coil at the same resonant frequency. The change in the current flowing in the coil at the same resonant frequency is sensed. In response to the current change at the same resonant frequency the particular object having the tuned circuit with the same resonant frequency as the frequency of the applied AC energy is indicated with a phase detector arrangement responsive to the changed current flowing in the coil at the same resonant frequency and a reference wave at the same resonant frequency. The phase detector arrangement derives indications of the polarities of the phase of quadrature components of the changed current relative to the reference wave and indicates the durations of the polarities relative to predetermined values therefor. | 66,468 |
RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 11/804,593, filed May 18, 2007 now U.S. Pat. No. 7,821,636, which claims the benefit of U.S. Provisional Application No. 60/802,088, filed on May 18, 2006. This application is also a continuation-in-part of U.S. application Ser. No. 11/804,589, filed May 18, 2007 now U.S. Pat. No. 7,772,579, which also claims the benefit of U.S. Provisional Application Nos. 60/927,832, filed May 4, 2007 and 60/802,087, filed on May 18, 2006.
The entire teachings of the above applications are incorporated herein by reference.
GOVERNMENT SUPPORT
This invention was made with government support under F 19628-00-C-0002 awarded by the DARPA, MTO. The government has certain rights in the invention.
BACKGROUND OF THE INVENTION
The ability to detect and classify small particles in a fluid stream has been of great use in many fields. For example, the detection of harmful particles or biological agent particles in air (outdoors or inside a building) or in water (a city water supply) may require monitoring the air or water for such particles.
SUMMARY OF THE INVENTION
Aerosol and hydrosol particle detection systems typically do not determine the exact location of an individual particle as it passes through the detection system sample volume. However, knowledge of the exact particle location has several advantages. These advantages include correction of systematic particle measurement errors due to variability of the particle position within the sample volume, targeting of particles based on position, capture of particles based on position, reduced system energy consumption and reduced system complexity.
An apparatus and method for use for detecting a location of a particle in a fluid stream is described herein. In one example embodiment, the apparatus for measuring a position of a particle in a flow comprises a light source that may be used to generate an illuminating beam to travel in a first dimension and define an illumination pattern in second and third dimensions. The apparatus may further comprise a light detector to detect a temporal profile of scattered light (including elastic scattering, luminescence, and/or Raman scattering) produced by the particle's passing through the illumination pattern in the second dimension. The apparatus may also include a processing unit, coupled to the light detector, to determine the position of the particle, in the third dimension relative to the illumination pattern, based on the temporal profile of the scattered light and a geometrical relationship of the illumination pattern.
The apparatus may further include a masking element in optical arrangement with the light source. The masking element may cause the illuminating beam to define a plurality of regions of the illumination pattern, where at least two regions may comprise varying intensities or polarizations. A specific example of the illuminating beam defining at least two regions of varying intensities of the illumination pattern is where at least one of the regions of the illumination pattern has a measurably different intensity than any of the other regions (i.e., a zero or substantially zero beam intensity).
In at least one example embodiment, the light source may be a first light source, the illuminating beam may be a first illuminating beam, the illuminating pattern may be a first illuminating pattern, the temporal profile may be a first temporal profile, and the scattered light may be a first scattered light. Thus, the apparatus may also include a second light source, which may generate a second illuminating beam to travel in a third dimension, the illuminating beam may define a second illumination pattern in first and second dimensions. The detector may further detect a second temporal profile caused by a second scattered light produced by the particle's passing through the second illuminating pattern. The processing unit may be configured to determine the position of the particle, in the first dimension relative to the second illumination pattern, which may be based on the second temporal profile of the second scattered light and a geometrical relationship of the second illumination pattern.
In another example embodiment, the apparatus may further comprise a modulator to modulate the intensity of the illuminating beam and the intensity of a second illuminating beam. The detector may be a first detector, and the apparatus may further comprise a second detector configured to detect the second temporal profile. The apparatus may also comprise a coding element configured to code distinctly the illumination pattern and the second illumination pattern.
In some example embodiments, the first and second light sources of the apparatus may be configured to illuminate the first illuminating beam and the second illuminating beam at different wavelengths. The apparatus may also comprise a polarizer, in optical arrangement with the light source to distinctly polarize the first illuminating beam and the second illuminating beam.
In another embodiment, the apparatus may further include a patterned optical block. The patterned optical block may comprise a plurality of blocking regions that may be positioned to receive the scattered light. The apparatus may comprise a light shield to shield the illuminating beam, in a manner allowing the scattered light to be received by the optical block, and may further comprise a focusing element to focus the scattered light onto the optical block. The detector may detect a combined temporal profile that may be produced by the particle's passing through the illumination pattern and the plurality of blocking regions on the optical block. The processing unit may determine the position of the particle, in the first dimension relative to the illumination pattern, that may be based on the combined temporal profile of the light scattering.
The processing unit may be configured to measure a relative amount of light of the combined temporal profile that may be blocked from the plurality of blocking regions with respect to an amount of light unblocked by the plurality of blocking regions. The apparatus may also comprise a calculation unit to determine a normalization or correction value, which may be based on a measurement from a standard particle at a known position, to apply to subsequent measurements of nonstandard particles at this same known position.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing will be apparent from the following more particular description of example embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating embodiments of the present invention.
FIGS. 1A and 1B are diagrams with examples of particle detection systems;
FIG. 2 is a schematic diagram of a patterned beam particle detection system for determining a position of a particle in one dimension, according to an embodiment of the present invention;
FIG. 3 is a flow diagram of an overview of operative steps of the detection system of FIG. 2 ;
FIG. 4 is a perspective view of an example patterned beam, defining an illumination pattern, illuminating particles in a sample volume of a flow, according to an embodiment of the present invention;
FIGS. 5A , 5 B and 5 C are a depiction of an example illumination pattern and measured signal produced by detecting particles by the systems illustrated in FIGS. 1A and 1B ;
FIGS. 6A and 6B are diagrams of example geometrical configurations of the illumination pattern;
FIG. 7 is a schematic diagram of a patterned beam particle detection system for determining a position of a particle in two physical dimensions in an air flow, according to an embodiment of the present invention;
FIG. 8 is a flow diagram of an overview of operations of the detection system of FIG. 7 ;
FIG. 9 is a depiction of an example of a polarization masking element, according to an embodiment of the present invention;
FIG. 10 is a schematic diagram of a patterned beam particle detection system featuring polarization coding for determining a position of a particle in two physical dimensions in an air flow, according to an embodiment of the present invention;
FIG. 11 is a schematic diagram of a patterned beam particle detection system featuring modulation coding for determining a position of a particle in two physical dimensions in an air flow, according to an embodiment of the present invention;
FIGS. 12A and 12B are schematic diagrams of a patterned beam particle detection system featuring illumination wavelength coding to determine a position of a particle in two physical dimensions in an air flow, according to an embodiment of the present invention;
FIGS. 13A and 13B are schematic diagrams of an optical block particle detection system for determining a position of a particle in an air flow, and an example measurement signal, respectively, according to an embodiment of the present invention;
FIG. 14 is a flow diagram of an overview of operations of the detection system of FIGS. 13A and 13B ;
FIGS. 15A and 15B are a schematic diagram of an optical block particle detection system for determining a position of a particle in an air flow and example measurement signals, respectively, according to an embodiment of the present invention;
FIG. 16 is a schematic diagram of an optical block and patterned beam particle detection system for determining two positions of a particle in an air flow, according to an embodiment of the present invention;
FIG. 17 is a flow diagram of an overview of operations of the detection system of FIG. 16 ;
FIG. 18 is a depiction of a measured signal that may be obtained using the system of FIG. 16 ; and
FIG. 19 is a depiction of a measurement normalization (or correction) using a patterned beam particle detection system, according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
A description of example embodiments of the invention follows.
FIG. 1A provides an example 100 of a particle detection system 101 . The particle detection system 101 may be situated to detect particles 104 in an airvent system 105 of a building 103 . The particle detection system 101 includes an inlet (not shown) in which an airflow enters the particle detection system 101 . An outlet 106 of the particle detection system 101 may be used as a pathway to shunt the airflow if particles 102 detected are deemed unsafe for breathing. Otherwise, the airflow can continue into the airvent system 105 .
As another example, a liquid stream may also need to be evaluated. For instance, a water reservoir may need to be continuously monitored to ensure harmful particles are not introduced into a water supply. FIG. 1B provides an example 107 of a particle detection system 111 detecting particles 113 in a liquid stream 109 . The particle detection system 111 may include an inlet 115 used to supply a sample of the liquid flow 109 to the particle detection system 111 . Once the liquid flow 109 has been checked for a presence of foreign particles, an outlet 117 may be used to remove the sample from the particle detection system 111 .
FIG. 2 provides an example of a particle detection system 200 according to an embodiment of the present invention. FIG. 3 shows a flow diagram 300 of an overview of operations that may be taken by the detection system 200 . Referring to FIG. 2 with references to FIG. 3 , the particle detection system 200 may include a light source 201 configured to emit a propagating beam 203 , also referred to herein as an “illuminating light beam,” traveling in the z dimension, or a first dimension. A masking element 205 may be coupled to the light source 201 to produce a light beam pattern 207 also referred to herein as an “illuminating pattern,” in x and y dimensions, or second and third dimensions, respectively ( FIG. 3 , 301 ). It should be appreciated that the light beam 207 shown in FIG. 2 is rotated 90 degrees about its vertical axis as represented in the Figure. It should also be appreciated that instead of the light beam pattern shown ( 207 ) any other light beam pattern may be employed in the detection system 200 .
The propagating light beam 203 defines the beam pattern 207 at a sample volume 209 within a particle flow 210 . The sample volume 209 may be configured to “receive” the flow in the x axis, or the second dimension. As the particles (not shown) in the sample volume 209 pass through the propagating beam 203 , defining the beam pattern 207 ( FIG. 3 , 303 ), a diverging light scattering 211 is produced as a result of a collision of photons with the particles passing through the beam pattern 207 .
The diverging light scattering 211 has a temporal profile that is a function of the beam pattern 207 . For example, for the beam pattern 207 , the temporal profile exhibits a first period of signal (i.e., scattering), short period of no or very low signal as the particle passes through the gap in the beam pattern, and then a second period of signal. Accordingly, the temporal profile has a timing indicative of the particle's position in the sample volume 209 in the y, or third, dimension. An optical focusing element 213 may be used to focus the produced diverging scattered light 211 , resulting in converging scattered light 217 . An optical beam blocker 215 may be used to block the propagating beam 203 , thereby preventing the propagating beam 203 from directly reaching the light detector 219 and, thus, preventing detector saturation. The converging scattering light 217 may be focused onto the light detector 219 for detection ( FIG. 3 , step 305 ).
In this example embodiment, the light detector 219 is coupled to a processing unit 221 . The light detector 219 may be configured send data measurements 223 to the processing unit 221 in the form of an analog electrical signal. The processing unit 221 may be configured to determine the position of the particle in the third dimension, relative to the illumination pattern 207 , based on the temporal profile of the detected scattered light 217 ( FIG. 3 , step 307 ). The processing unit 221 may send measurement instructions 225 to the light detector 219 in the case of intelligent, programmable configurable. The measurement instructions 225 may include, for example, on/off instructions. The light detector 219 and the processing unit 221 may be connected via a connection link 227 . It should be appreciated that the connection link 227 may be a wired, optical, or wireless connection, or any other data transfer connection known in the art.
The processing unit 221 may also be connected to a database storage 229 . The processing unit 221 may send the database storage 229 a particle identification request, and/or a data storage request 231 . The data storage request 231 may include the data measurements 223 , or representation thereof, provided by the light detector 219 . The particle identification request may include a request to compare information stored in the database storage 229 with the obtained data measurements 223 , optionally for the purpose of classifying and identifying the particles in the sample volume 209 . The database storage 229 may send a particle identification result 233 to the processing unit 221 . The particle identification result 233 may comprise a listing of possible particle matches with respect to the data measurements 223 .
The processing unit 221 may also be coupled to a network 237 . The processing unit 221 may send a particle identification request, a data storage request, and/or a data sharing request 239 to the network 237 . The particle identification request and data sharing request 239 may be similar to the request 231 sent to the database storage 229 . The data sharing request 239 may be a request to share data with a user 236 that may be connected to the network 237 , or another detection system 238 that may be connected to the network 237 . The network 237 or, more specifically, a server or other network element (not shown) connected to the network 237 , may also send a message 241 in the form of particle identification results, similar to the result 233 sent by the database storage 229 , or instructions to the processing unit 221 . The instructions 241 may be comprise measurement instructions similar to the instructions 225 sent to the light detector 219 .
The database storage 229 and the network 237 may also include a bidirectional data transfer connection 249 . The database storage 229 may send identification results and/or a data sharing request 247 to the network 237 . The network 237 may send an identification request 245 to the database storage 229 . It should be appreciated that the data transfer connections 235 , 243 , and 249 between the processing unit and the data storage, the processing unit and the network, and the network and the data storage, respectively, may include or be supported by any data transmission link known in the art. It should also be appreciated that the configuration shown in FIG. 2 of the particle detection system 200 is merely an example. Any other dimensional configuration may be employed, preferably with the first, second, and third dimensions orthogonal to one another.
FIG. 4 provides an expanded view 400 of the intersection of the particle air flow 402 and the propagating light beam 403 , resulting in a sample volume 409 . The propagating light beam 403 may be configured to travel in the z, or first, dimension. As is shown in FIG. 4 , the propagating light beam 403 may comprise a light beam pattern 407 , similar to the pattern 207 shown in FIG. 2 . The light beam pattern 407 may, for example, be defined by a square shaped beam with a center diagonal region having an intensity that is substantially equal to zero or substantially less than the intensity of the surrounding portion(s) of the light beam pattern. The particle air flow 402 may be transmitted in the x, or second, dimension. The sample volume 409 may include any number of particles 410 traveling in the particle air flow. However, it is expected that only one particle at a time will pass through the sample volume 409 at a time or, if more than one particle passes through at a time, they pass through at positions sufficiently distinguishable from each other. It should be appreciated that any geometrical configuration may be employed, provided that the first, second, and third dimensions are orthogonal to each other, in a preferred embodiment.
FIG. 5A provides a detailed schematic diagram 500 of an example light beam pattern 502 . The light beam pattern 502 may be formed with different regions of varying intensity. For example, the pattern 502 may include a first region 501 , second region 503 , and third region 505 , with the second region 503 having an intensity that may be measurably less (e.g., 5%, 20%, 50%, 80%, or 100% less) than the intensity of the first and/or third regions 501 , 505 , respectively. An angle θ 507 defines a sloping of the diagonal second region 503 in this example embodiment. A label ‘x 0 ’ 509 represents the smallest distance a particle (not shown) may pass through the first region 501 before reaching the second region 503 . The light beam pattern 502 may be defined by a total distance (D) 511 . A position of the particle in the y, or a third, dimension 513 represents a transverse location of the particle in a particle path 515 . The transverse location y may be obtained using the geometrical properties of the beam pattern 502 and the temporal profile (described in reference to FIG. 5B below) produced by the particle's passing through the light beam pattern 502 and the geometric properties of the beam pattern.
FIG. 5B represents an example of a measured light signal produced by a particle in the particle path 515 traveling through the beam pattern 502 . The measured light signal 515 may comprise three distinct portions. The first portion, labeled t 1 , 521 represents the time the particle in the particle path 515 took to pass through the first region 501 of the light beam pattern 502 . As the particle in the particle path 515 passes through the first region 501 of the beam pattern 502 , the particle may produce a scattered light, of an intensity represented as a signal level in the region t 1 521 of the measured light signal 517 . As the particle in the particle path 515 passes through the second region 503 of the light pattern 502 , no scattered light, or a substantially small amount of scattered light, may be produced due to the low intensity of the second region 503 . Therefore, the region labeled as t 2 523 of the measured light signal 517 has a very low intensity reading as compared to that of t 1 521 . The region labeled as t 3 525 is a representation of the measured scattered light produced by the particle in the particle path 515 passing through the third region 505 of the light beam pattern 502 . As expected, the signal reading in the region t 3 525 is greater than that of t 2 523 , since the third region of the pattern 505 has a greater intensity than that of the second region 503 .
It should be understood that the intensities of the light beam pattern 502 may be inverted such that the first and third regions 501 , 505 are dimmer (i.e., have less intensity) than the second region 503 . In this alternative light beam pattern 502 example, the measurements at t 1 , t 2 , and t 3 are based on the inverted levels of intensity. The relative timing is dependent only on the geometry of the intensity pattern 502 . The absolute timing additionally depends on the velocity of the particle through the pattern 502 .
FIG. 5C is a graphical representation 527 of the measured light signal 517 from a real particle. The graphical representation 527 is a plot of the intensity signal measured in millivolts (mv) 529 versus the entire time the particle passed through the light beam pattern 502 , measured in milliseconds (ms) 531 . The time signals t 1 521 and t 3 525 include high intensity signal readings since the first and third regions 501 and 505 , respectively, of the light beam pattern 502 have light with a substantial greater intensity than that of the second region 503 , represented by the intensity reading t 2 523 . Therefore, the first and third regions 501 and 505 produce a greater amount of scattered light when the particle passes through. The measurement t 2 523 provides a very low intensity signal reading in this example due to the fact that the light intensity of the second region 503 is substantially less than the first and third regions 501 and 505 , respectively, therefore producing a lesser amount of scattered light when the particle passes through it.
FIGS. 6A and 6B provide a depiction of the geometric relationship between the particle in the particle path and the patterned light beam 600 a . In FIG. 6A the patterned beam 600 a may include different regions of varying intensity. For example, the patterned light beam 600 a a first region 601 , second region 603 , and third region 605 , with the second region having an intensity that may be substantially less than the intensity of the first and/or third regions 601 , 605 , respectively. The time taken for a particle to pass through the first 601 , second 603 , and third 605 regions is represented by t 1 615 , t 2 617 , and t 3 619 , respectively. An angle θ 607 defines a sloping of the diagonal second region 603 in this embodiment. The label ‘x 0 ’ 609 represents the smallest distance a particle may pass through the first region 601 before reaching the second region 603 . The light beam pattern 600 a may be defined by a total distance (D) 611 . A position of the particle in the y, or third, dimension 613 , representing a transverse location of the particle in a particle path 612 may be obtained using the geometrical properties of the pattern 600 a and time signals by t 1 615 , t 2 617 , and t 3 619 . The label ‘x’ 621 represents a side of a triangle, formed in the first region 601 , by the transverse position y 613 and the angle θ 607 . The term ‘vt 1 ’ represents a mathematical expression of the distance traveled in the first region 601 by the particle in the particle path 612 .
Using the geometrical configuration described above, it should be appreciated that the total time taken for a particle to pass through the pattern beam 600 a may be represented by equation (1):
T=t 1 +t 2 +t 3 (1)
The relationship between a total distance (D) and a total time (T) may be used to find a velocity (v) of the particle traveling in the particle path 612 , as shown in equation (2):
v = D T ( 2 )
Using the tangent relationship of the angle θ 607 with respect to the transverse position y 613 and x 621 , equation (3) may be derived:
y x = tan ( θ ) ( 3 )
Solving for x in equation (3) yields the following equation:
x = y tan ( θ ) ( 4 )
Using the geometrical relationship between ‘vt 1 ’ 623 , x 0 609 , and x 621 shown in FIG. 6A , the following equation may be obtained:
x 0 +x=vt 1 (5)
Since the value of the distance (D) 611 of the pattern 600 a may be substantially small, it may be assumed that the velocity of the particle traveling the first region 601 is equal to the velocity of the particle traveling through the entire pattern. Thus, the value for the particle velocity (v) obtained in equation (2) may be substituted into equation (5) yielding:
x 0 + x = v t 1 = D t 1 T ( 6 )
Substituting the value of x from equation (4) into equation (6) yields:
x 0 + y tan ( θ ) = vt 1 = D t 1 T ( 7 )
Finally, solving for the transverse particle position value (y) in equation (7) yields:
y = ( Dt 1 T - x 0 ) tan ( θ ) ( 8 )
Thus, based on the measurements t 1 615 , t 2 617 , and t 3 619 , as well as knowledge of the total distance (D) 611 , ‘x 0 ’ 609 , and the angle θ 607 , the transverse particle position y 613 may be obtained.
FIG. 6B shows an alternative geometrical confirmation of the beam pattern 600 b that may be used for finding the transverse particle position y 613 . The beam pattern 600 b comprises a majority of the geometrical relationships of the previous beam pattern 600 a with a few differences. In beam pattern 600 b , the label ‘x 0 ’ 633 represents the smallest distance a particle may pass through the first region 601 before reaching a center 634 of the second region 603 . The label ‘x’ 643 is the distance between the center 634 and an intersection center 635 . The intersection center 635 may represent a location where the particle, traveling in the particle path 612 , intersects with the center of the second region 603 . The label ‘vT 1 ’ is a mathematical expression representing the total distance traveled in the first region 601 through the center of the second region 603 , with timing signal T 1 639 representing the time of travel. The timing signal T 2 641 represents the remaining time of travel, or the time of travel between the center of the second region 603 through the end of the third region 605 . T 2 641 may be obtained from a graph similar to the graph 527 shown in FIG. 5C (i.e., T 2 =t 2 /2).
Using the mathematical relationships of equations (1)-(8), a value for the transverse particle position y 613 may be obtained for the configuration of pattern 600 b :
y = ( DT 1 T - x 0 ) tan ( θ ) ( 9 )
It should be appreciated that any other geometrical pattern configuration may be employed in the determination of the transverse particle position y 613 from timing measurements. Additionally, it should be appreciated that the light beam pattern need not have sharp edges or a binary intensity profile, as shown in FIGS. 6A and 6B . It is only required that the light beam pattern provides distinct timing signals for transverse particle paths separated by resolution distances of interest.
FIG. 7 shows a depiction of a particle detection system 700 capable of producing two particle positions, one position in a transverse position (the y, or third, dimension) and a particle position in a longitudinal direction (the z, or first, dimension). FIG. 8 shows a flow diagram 800 of an overview of operations that may be taken by the detection system 700 . It should be appreciated that the operations described in FIG. 3 are also performed in the detection system 700 of FIG. 7 .
Referring to FIG. 7 , the particle detection system 700 includes a light source 701 configured to produce a propagating light beam 703 in the z, or first, dimension in this example embodiment. The light source 701 may be coupled to a masking element 705 , such that once the light source 701 illuminates the masking element 705 , a light beam pattern 707 is produced in the propagating beam 703 in the x, or second, and y, or third, dimensions. The propagating beam 703 comprising the light pattern 707 may be configured to intersect a sample volume 709 through which a particle flow flows in the x, or second, dimension. As the particles in the sample volume 709 pass through the light beam pattern 707 of the propagating beam 703 , a diverging scattered light 711 may be produced. Similar to the light scattering 211 of FIG. 2 , the diverging light scattering 711 defines a temporal profile. The temporal profile has defined therein timing values indicative of the particle's position, in the sample volume 709 , in the y, or third, dimension. The diverging scattered light 711 and the propagating beam 703 may be passed through an optical focusing element 713 , resulting in a converging scattered light 717 . The patterned beam 703 may be blocked by a light beam block 715 in order to prevent a first light detector 719 from receiving the beam 703 , thus reducing the risk of detector saturation. The converging scattered light 717 may be focused onto the light detector 719 .
The particle detection system 700 may also include a second light source 721 that may be configured to produce a propagating beam 723 in a y, or third, dimension. The light source 721 may be coupled to a masking element 725 in order to produce a light beam pattern 727 in the propagating beam 723 in the x, or second, and z, or first, dimensions ( FIG. 8 , 801 ). The propagating beam 723 may then be passed through the sample volume 709 . Once the particles in the sample volume 709 pass through the light pattern 727 in the propagating beam 723 , a diverging scattered light 729 may be produced. An optical focusing element 731 may be used to focus the pattern beam 723 onto a light beam block 733 , thus preventing a saturation of a second light detector 737 . The focusing element 731 may also be used to focus the diverging scattered light 729 , resulting in converging scattered light 735 . The converging scattered light 735 may define a temporal profile. The temporal profile may include timing values indicative of the particle's position, in the sample volume 709 , in the z, or first, dimension. The converging scattered light 735 may be focused onto the second light detector 737 in order to detect the temporal profile provided by the scattering light 735 ( FIG. 8 , 803 ).
The light detectors 719 and 737 may be coupled to a processing unit 739 . The light detectors 719 and 737 may be configured to send data measurements 741 and 743 , respectively, to the processing unit 739 . The processing unit 739 may be configured to determine the position of the particle in a y, or third, dimension in the sample volume 709 using the measurement data 741 provided by the first light detector 719 . The processing unit 739 may also be configured to measure the position of the particle in the z, or first, dimension in the sample volume 709 using the measurement data 743 provided by the second light detector 737 ( FIG. 8 , 805 ). The processing unit 739 may be configured to send measurement instructions 745 and 747 to the light detectors 719 and 737 , respectively. The instructions 745 and 747 may, for example, include on/off instructions. A data link 749 between the light detector 737 and the processing unit 739 and a data link 751 between the light detector 719 and the processing unit 739 may be any form of data transmission link known in the art. It should also be appreciated that the database and network connections of FIG. 2 may also be employed in the particle detection system 700 shown in FIG. 7 .
It should also be appreciated that the masking element described in reference to FIGS. 2 , 4 , and 7 herein may, as an alternative to producing intensity variation, produce a beam pattern with portions of varying polarization.
FIG. 9 shows a masking element 900 comprising a polarization inducing section 901 configured to produce a beam pattern comprising portions of varying polarization.
FIG. 10 is an example of a particle detection system 1000 capable of obtaining a particle position in a transverse, or y (third), dimension and a longitudinal direction, or z (second), dimension. The particle detection system 1000 may include a first light source 1001 configured to produce a propagating beam 1003 in the z, or first, dimension. The light source 1001 may be coupled to a polarizing element 1005 . The polarizing element 1005 may be coupled to a first polarization processor 1007 . The first polarization processor 1007 may provide polarization instructions 1009 to the polarizing element 1005 . The polarizing element 1005 may induce a first polarization 1111 in the propagating beam 1003 . A masking element 1113 may also be coupled to the light source 1001 , in order to produce a light beam pattern 1114 , in the x, or second, and y, or third, dimensions, in the propagating beam 1003 . The propagating beam 1003 may be configured to pass through a sample volume 1115 , comprising a particle flow in an x, or second, dimension.
As a result of the particles in the sample volume 1115 passing through the light beam pattern 1114 of the propagating beam 1003 , a diverging scattered light 1117 is produced. The diverging scattering light 1117 may define a temporal profile. The temporal profile may be used to determine timing signals that are, in turn, used to determine a particle location in a y, or third, dimension. An optical focusing element 1119 may be configured to focus the diverging scattering light 1117 resulting in a converging scattering light 1121 . The converging scattering light 1121 may be configured to pass through a first polarizer 1123 resulting in a filtration of the converging scattering light 1121 , thus allowing only light having the first polarization 1111 to be passed through and focused on a first light detector 1125 . Since the scattered light is focused off-axis with respect to the propagating beam 1003 , a beam block is not needed in this configuration.
The particle detection system 1000 may also include a second light source 1127 configured to produce a propagating beam 1129 in a y, or third, dimension. The light source 1127 may be coupled to a second polarizing element 1131 . The second polarizing element 1131 may be coupled to a second polarization processor 1133 . The second polarization processor 1133 may provide polarization instructions 1135 to the second polarizing element 1131 . The polarization instructions 1135 may be used by the second light source 1127 to produce a second polarization 1137 in the propagating beam 1129 . A masking element 1139 may be coupled to the light source 1127 in order to produce a second light beam pattern 1140 . The propagating beam 1129 , comprising the light beam pattern 1140 and the second polarization 1137 , may be configured to pass through the sample volume 1115 .
As the particles in the sample volume 1115 pass through the light beam pattern 1140 a diverging scattering light 1141 may be produced. A second optical focusing element 1143 may be configured to focus the diverging scattering light 1141 , resulting in a converging scattering light 1145 . The converging scattering light 1145 may be configured to pass through a second polarizer 1147 , thus resulting in the filtering of the converging scattering light 1145 and, therefore, allowing only light featuring the second polarization 1137 to pass through. The filtered light is then focused onto a second light detector 1149 . Since the scattered light is focused off-axis with respect to the propagating beam 1129 , a beam block is not needed in this configuration.
The particle detection system 1000 may also employ a processing unit 1151 coupled to the first light detector 1125 and the second light detector 1149 . The first and second light detectors 1125 and 1149 , respectively, may provide data measurements 1153 and 1155 , respectively, to the processing unit 1151 . The processing unit 1151 may be configured to determine a particle position in the y, or third, and z, or first, dimensions using the supplied data measurements 1153 and 1155 , respectively. The determined particle positions may be based on timing signals obtained from the respective temporal profiles. The processing unit 1151 may also provide measurement instructions 1157 and 1159 to the first and second light detectors 1125 and 1149 , respectively via communications links 1158 , 1161 . The instructions 1157 and 1159 may comprise on/off instructions.
The processing unit 1151 may also be coupled to the first and second polarization processing units 1007 and 1133 , of the first and second light sources 1001 and 1127 , respectively. The processing unit 1151 may provide a polarization request 1163 and 1165 to the first and second polarization processing units of the first and second light sources, respectively. The polarization requests 1163 and 1165 provide polarization settings for the light sources 1001 and 1127 , respectively. The first and second polarization processing units of the first and second light source 1007 and 1133 , respectively, may also provide a polarization status 1167 and 1169 , respectively, to the processing unit 1151 . The polarization status 1167 and 1169 may provide a current polarization setting of the polarizing elements 1005 and 1131 , respectively. It should be appreciated that the database and networking connections shown in FIG. 2 may also be implemented in the particle detection system 1000 of FIG. 10 .
FIG. 11 illustrates another configuration of a particle detection system 1181 which may provide a particle position in a transverse (y), or third, dimension, and in a longitudinal (z), or first, dimension. In contrast to the detection systems shown in FIGS. 7 and 10 , the detection system 1181 may be configured to use a single light detector 1225 . The detection system 1181 may employ a first light source 1183 configured to provide a propagating beam 1185 in the z, or first, dimension. A coding element 1187 may be coupled to the first light source 1183 . In the configuration shown in FIG. 11 , the coding element 1187 may be a modulator configured to provide temporal modulation, resulting in a frequency setting (f 1 ) induced in the first light source 1183 . Thus, the illumination of the beam 1185 includes a first frequency 1193 . A processor 1189 may be coupled to the first coding element 1187 in order to provide frequency settings 1191 . A masking element 1195 may be coupled to the first light source 1183 in order to provide a light beam pattern 1197 in the x, or second, and y, or third, dimensions, in the propagating beam 1185 . The propagating beam 1185 comprising the light beam pattern 1197 , and illuminating at a first frequency 1193 may be configured to pass through a sample volume 1199 comprising a flow of particles in an x, or second, dimension.
The particle detection system 1181 may also comprise a second light source 1203 configured to provide an illuminating beam 1205 in the y, or third, dimension. A second coding element 1207 may be coupled to the second light source 1203 in order to provide a second frequency (f 2 ) 1213 to the illuminating beam 1205 . A second modulation processor 1209 may be coupled to the second coding element 1207 in order to provide frequency setting 1211 , providing a value of the second frequency 1213 . A masking element 1215 may be coupled to the second light source 1203 in order to provide a second light beam pattern 1217 in a z, or first, and x, or second, dimensions. The propagating beam 1205 , comprising the light beam pattern 1217 and illuminating at a second frequency 1213 , may be configured to pass through the sample volume 1199 with the particle flow in an x, or second, dimension.
As the particles in the sample volume 1199 pass through the light beam patterns 1197 and 1217 of the propagating beams 1185 and 1205 , respectively, a combined diverging scattering light 1219 is produced. The diverging scattering light 1219 defines a temporal profile comprising position information about the particles in the z, or first, and y, or third, dimensions, in the sample volume 1199 . The light scattering produced by the first light beam pattern 1197 may produce information indicative of a particle position in the y, or third, dimension. The light scattering produced by the second light beam pattern 1215 may produce information indicative of a particle position in the z, or first, dimension.
An optical focusing element 1221 may be configured to focus the diverging scattering light 1219 , resulting in a converging scattering light 1223 . The converging scattering light 1223 is focused onto a light detector 1225 . First and second bandpass filters 1229 and 1231 , respectively, may be coupled to the light detector 1225 . In this example embodiment, the light detector 1225 sends measured data 1227 to the first and second bandpass filters 1229 and 1231 , respectively. The first bandpass filter 1229 may be configured to filter out all data in the measured signal 1227 not having information of the first frequency 1193 . Similarly, the second bandpass filter 1231 may be configured to filter out all data in the measured signal 1227 not having information of a second frequency 1213 .
A processing unit 1233 may be coupled to the first and second filters 1229 and 1231 , respectively. In this example embodiment, the first and second bandpass filters 1229 and 1231 , respectively, are configured to provide filtered measurement data 1235 and 1237 , respectively, to the processing unit 1233 . The processing unit 1233 may be configured to determine a particle position in the y, or third, and z, or first, dimensions using the filtered data 1235 and 1237 , respectively. The determined particle positions may be based on timing signals obtained from the temporal profile. The processing unit 1233 may be configured to provide filtering or detection instructions 1239 and 1241 to the first and second filters 1229 and 1231 , respectively. The filtering instructions 1239 and 1241 may include on/off commands as well as frequency detection settings.
The processing unit 1233 may also be coupled to the first and second modulation processors 1189 , 1209 of the first and second light sources 1183 and 1203 , respectively. The processing unit 1233 may send coding instructions 1247 and 1249 to the first and second modulation processors 1189 and 1209 , respectively. The coding instructions 1247 and 1249 may contain frequency settings used to program the first and second coding elements 1187 and 1207 , respectively. The first and second modulation processors 1189 and 1209 may be configured to send a coding status 1251 and 1253 , respectively, to the processing unit 1233 . The coding status 1251 and 1253 may comprise information of a current frequency setting. It should be appreciated that the particle detection system 1181 may also employ the database and network configurations shown in FIG. 2 .
FIG. 12A illustrates a particle detection system 1261 capable of determining a particle position in a transverse (y), or third, dimension, and a longitudinal (z), or first, dimension. The particle detection system 1261 may employ a first light source 1263 configured to provide a propagating beam 1265 in the z, or first, dimension. A first coding element 1267 may be coupled to the first light source 1263 . A first coding processor 1269 may be coupled to the first coding element 1267 in order to provide coding instructions 1271 . In the example shown in FIG. 12A , the coding instructions may be wavelength instructions used for selecting an illumination wavelength of the first light source 1263 . A masking element 1275 may be coupled to the first light source 1263 in order to provide a light beam pattern 1277 in the y, or third, and x, or second, dimensions. The propagating beam 1265 , comprising the selected wavelength 1273 and light beam pattern 1277 , may be configured to pass through a particle flow in a sample volume 1279 . As the particles in the sample volume 1279 pass through the light beam pattern 1277 , a diverging scattering light 1281 is produced. The diverging scattering light 1281 may be configured to pass through a first filter 1283 allowing light of only the selected wavelength 1273 to pass through. An optical focusing element 1285 may be configured to focus the diverging scattering light 1281 resulting in converging scattering light 1287 focused onto a light detector 1289 .
The particle light detection system 1261 may also employ a second light source 1291 configured to provide a propagating beam 1293 in the y, or third, dimension. A second coding element 1295 may be coupled to the second light source 1291 . A second coding processor 1297 may be coupled to the second coding element 1295 in order to provide coding instructions 1299 . The coding instructions 1299 may include wavelength illumination instructions used in selecting a second wavelength 1301 for an illumination produced by the second light source 1291 . A masking element 1303 may be coupled to the second light source 1291 in order to produce a second light beam pattern 1305 in the z, or first, and x, or second, dimensions. The propagating beam 1293 , including the second selected wavelength 1301 and the second light beam pattern 1305 , may be configured to pass through the sample volume 1279 . As the particles in the sample volume 1279 pass through the second light beam pattern 1305 , a second diverging scattering light 1307 may be produced. A second filter 1309 may be configured to filter the diverging scattering light 1307 , such that only light comprising the second selected wavelength 1301 may pass. A second optical focusing element 1311 may be configured to focus the diverging scattering light 1307 resulting in a converging scattering light 1313 being focused on a second light detector 1315 .
The particle detection system 1261 may also comprise a processing unit 1317 coupled to the first and second light detectors 1289 and 1315 , respectively. The processing unit 1317 may be configured to provide measurement instructions 1319 and 1325 to the first and second particle detectors 1289 and 1315 , respectively. The measurement instructions 1319 and 1325 may provide on/off commands or wavelength detection settings. The first and second light detector 1289 and 1315 may be configured to provide data measurements 1323 and 1325 , respectively, to the processing unit 1317 . The processing unit 1317 may be configured to determine a particle position in the y, or third, and z, or first, dimensions using the supplied data measurements 1323 and 1325 , respectively. The determined particle positions may be based on timing signals obtained from the respective temporal profiles. The processing unit 1317 may also be coupled to the coding processors of the first and second light sources 1269 and 1297 , respectively. The processing unit 1317 may provide coding instructions 1331 and 1333 to the first and second coding processors 1269 and 1297 , respectively. The first and second coding processors 1269 and 1297 may provide a coding status 1335 and 1337 , respectively, to the processing unit 1317 . It should be appreciated that the database and network connections of FIG. 2 may also be incorporated into the particle detection system 1261 . It should also be appreciated that data transmission links 1339 , 1341 , 1327 , and 1329 may comprise any data transmission link known in the art.
FIG. 12B provides an alternative configuration 1345 of the particle detection system shown in FIG. 12A . The alternative configuration 1345 provides a more compact system. Instead of employing two filters, as shown in the particle system 1261 , a single dichroic filter 1353 may be used. Thus, as the particles in the sample volume 1279 pass through the light beam patterns 1277 and 1303 , a combined diverging scattering light 1347 is produced. The combined scattering light 1347 may define a temporal profile indicative of a particle position in the z, or first, dimension, and y, or third, dimension. The temporal profile may provide timing signals indicative of particle position to be used by the processing unit 1317 .
An optical focusing element 1349 may be used to focus the combined diverging scattering light 1347 in order to produce a converging scattering light 1351 . Upon passing the dichroic filter 1353 , the converging scattering light 1351 may be decomposed into a first converging scattering light 1355 of the first selected wavelength 1273 and a second converging scattering light 1357 of the second selected wavelength 1301 . The first filtered scattering light 1355 may be focused onto a first light detector 1289 and the second scattering light 1357 may be focused onto the second light detector 1315 .
FIG. 13A provides illustrations of a particle detection system 1361 in examples a-d that may provide a longitudinal particle position in a z, or first, dimension. FIG. 14 provides a flow diagram describing an overview the operations taken by the particle detection system 1361 . Referring to FIGS. 13A and 14 , in the first particle detection system 1361 a , an illumination beam 1365 may be configured to travel in the z, or first, dimension ( FIG. 14 , 1401 ). The illumination beam 1365 may further be configured to intersect a sample volume 1363 through which particles traveling in an x, or second, dimension travel. The particles may travel, for example, in a top path 1364 a , center path 1364 b , or bottom path 1364 c . The top, center and bottom paths represent different positions of the particle in the z, or first, dimension.
As the particle travels in the x, or second, dimension and passes through the illumination beam 1365 , a diverging scattering light 1367 may be produced ( FIG. 14 , 1405 ). The diverging scattering light 1367 may define a temporal profile that may, by the scattering, further include information indicative of the particle position in the z, or first, dimension. An optical focusing element 1369 may be configured to focus the diverging scattering light 1367 , resulting in a converging scattering light 1370 . A light blocker 1371 may be used to block the illumination beam 1365 , thus preventing a photodetector 1375 from “seeing” the illumination beam 1365 , and, therefore, preventing detector saturation. The converging scattering light 1370 may be focused onto a patterned optical block 1373 a , 1373 b , 1373 c placed in front of the detector 1375 ( FIG. 14 , 403 ). The optical block 1373 a - c may include three sections, for example, a top section 1373 a , center section 1373 b , and bottom section 1373 c . The top and bottom sections of the optical block 1373 a , 1373 c may use blocking sections 1374 and 1376 , respectively, which may partially or completely block the scattering light 1370 from reaching the photodectector 1375 ( FIG. 14 , 1407 ). Measuring a relative amount of light blocked by the blocking patterns 1374 and 1376 , with respect to an amount of unblocked light, may provide information about where the particle is traveling in the z, or first, dimension ( FIG. 14 , 1409 ).
FIG. 13B provides an example of measured signals which may be obtained using the particle detection system 1361 . The top path signal 1384 provides an example signal that may be obtained from a particle traveling along the top path 1364 a , as shown in the system in FIG. 13A . As shown in FIG. 13A , a particle traveling along the top path 1363 a results in a converging scattering light 1370 that is focused on the top layer of the optical block 1373 a , while the light scattering may be transmitted through the center and bottom layers of the optical beam block 1373 b and 1373 c , respectively. Therefore, the top path signal 1384 includes a “clear blocking” section 1385 , indicating that the particle has traveled along the top path 1364 a . If the particle has traveled only along the top path 1364 a , then only the top path signal 1384 may includes the clear blocking portion 1385 . As illustrated in FIG. 13B , the center and bottom path signals 1387 and 1390 , respectively, do not have a clear blocking section 1385 if the particle is traveling along the top path 1364 a.
As also illustrated in FIG. 13A , if a particle is traveling along the bottom path 1364 c of the sample volume 1363 , then only the bottom path signal 1390 includes a clear blocking portion 1392 . If the particle is traveling along the center path 1364 b of the sample volume 1363 , then neither the top nor bottom path signal 1384 , 1390 has a blocking portion. Based on which signal 1384 , 1387 , 1390 , a determination can be made as to which path 1384 a - c the particle traveled.
As is shown in FIG. 13B , a particle traveling in the top portion, regardless of its position in the x, or second, dimension, may produce scattered light that only focuses on the top portion of the optical block 1373 a , thus being “transparent” to the middle and bottom portions of the optical block 1373 b and 1373 c , respectively. Similarly, as seen in the particle detection systems 1361 , example c, a particle traveling in the bottom path 1364 c of the sample volume 1363 may produce scattering light 1381 that may only be focused on the bottom layer of the optical block 1373 c . Therefore, the produced scattered light 1380 may be capable of being transmitted through the top and middle layers of the optical block 1373 a and 1373 b , respectively. As seen from the optical particle system 1361 , example d, the particle traveling in the bottom path, regardless of its position in the x, or second, dimension, is only focused on the bottom layer of the optical beam block 1376 .
FIG. 15A shows a particle detection system similar to that of FIG. 13A , with the particle detection system in FIG. 15A employing a pattern light block 1513 with an alternative blocking pattern. The blocking pattern of optical block 1513 includes blocking edges, rather than the blocking regions of optical block 1373 a - c of FIG. 13A . FIG. 15B provides example measurement signals which may be obtained from the particle detection system of FIG. 15A through use of the alternative blocking pattern of the optical block 1513 . A particle traveling in the top path 1504 a of the particle path 1503 may only be focused on a top portion 1514 a of the optical block 1513 . The resulting signal 1517 may comprise a completely blocked portion 1519 of a first portion of the obtained signal and an unblocked portion 1521 in a second portion of the signal 1517 indicative of the particle traveling in the top path 1504 a . A particle traveling in the bottom path 1504 c of the particle path 1503 may only be focused on the bottom portion 1514 c of the optical block 1513 . The resulting signal 1527 may represent an unblocked region 1529 in a first portion of the signal and a blocked region 1531 in a second portion of the signal. Finally, a particle traveling in the center path 1504 b may only be focused in the center portion 1514 b of the optical block 1513 . The resulting signal 1523 may not comprise any portions indicative of a blocked signal, but only a portion representing an unblocked signal 1523 .
FIG. 16 provides an example of a particle detection system 1600 capable of providing two particle positions in a longitudinal (z), or first, dimension, and a transverse (y), or third, dimension. The particle detection system 1600 may include a light source 1601 configured to provide a propagating beam 1603 propagating in the z, or first, dimension. A masking element 1605 may be coupled to the light source 1601 and may be configured to produce a light beam pattern 1607 in an x, or second, and y, or third, dimension, in the propagating beam 1603 . As the propagating beam 1603 , defining the light pattern 1607 , is passed through a sample volume 1609 comprising particles, the particles passing through the light beam pattern 1607 may produce diverging scattering light 1611 . An optical focusing element 1613 may be used to focus the diverging scattering light 1611 , therefore producing converging scattering light 1617 . An optical blocker 1615 may be used to block the illuminating beam 1603 , thus preventing the light detector 1625 from receiving light from the illuminating beam 1603 and becoming saturated. The converging scattering light 1615 may be configured to pass through an optical beam block 1619 . Upon passing through the optical beam block 1619 , a partially blocked scattered light 1621 may be configured to be detected by the light detector 1623 .
FIG. 17 is a depiction of a flow diagram 1700 of an overview of the operations that may be taken by a processing unit 1625 . The processing unit 1625 may be coupled to the light detector 1623 . The light detector 1623 may provide data measurements 1629 to the processing unit 1625 ( 1701 ). The processing unit 1625 may provide measurement instructions 1631 , which may comprise on/off directions, to the light detector 1623 .
Using the temporal profile, the processing unit 1625 may process the profile in order to obtain multiple timing values, similar to the timing signals discussed in relation to FIGS. 5B , 5 C, 6 A, and 6 B ( 1703 ). The processing unit 1625 may further be configured to determine a position of the particle in a transverse (y), or third, dimension using the timing values obtained from the temporal profile ( 1705 ).
Using blocking information obtained from the optical block 1619 , the processing unit 1625 may be configured to measure a relative amount of light blocked from the blocking regions of the light block, with respect to an amount of light unblocked by the plurality of blocking regions ( 1707 ). The processing unit may be further configured to determine a position of the particle in the longitudinal (z), or first, dimension, based on the relative amount of light blocked ( 1709 ). It should be appreciated that the processing unit 1625 may comprise the database and network configurations shown in FIG. 2 .
FIG. 18 provides an example of a measurement signal 1819 which may be obtained from the particle detection system of FIG. 16 . The resulting measurement signal 1819 may be produced by the addition of the measurement signal obtained from the pattern beam 1801 and the measurement signal obtained from the optical pattern block 1809 . Similar to the measurement signal shown in FIG. 5B , the measurement signal obtained from the patterned light beam 1801 may comprise three portions indicative of a time value representing the time the particle passed through the three sections of the pattern beam. In this example, t 1 represents the time the particle passed through the first section of the pattern beam, t 2 represents the time the particle passed through a second section of the pattern beam, and t 3 represents the time taken for the particle to pass through the third section of the pattern beam ( FIG. 5A ).
The measurement signal obtained by the pattern light block 1809 illustrates an example of a signal obtained from a particle traveling in the top path of the sample volume, as illustrated in FIG. 13B . The exact particle location in the z, or first, dimension may be obtained empirically from the measured signal, for example in a similar manner as was previously described in relation to FIG. 13B . The exact particle location in the z, or first, dimension may also be found quantitatively using the timing values t 4 -t 6 , 1811 - 1817 respectively, and amplitudes a and b, 1813 and 1815 respectively. The quantitative method of finding the particle location in the z, or first dimension may rely not only on the timing values supplied by the temporal profile, but may also rely on the optical system that focuses the scattered light on to the patterned light block.
FIG. 19 illustrates an example application for which the particle position detection system may be used. Region 1901 illustrates a light beam 1903 that induces fluorescence in particles it illuminates and particles traveling in a top 1905 a , or a center 1905 b , or a bottom 1905 c particle path. Fluorescent signals 1907 , 1909 , and 1911 represent the measured signals obtained from identical particles traveling in the top, center, and bottom paths, respectively. As is shown in the figure, the signal obtained from the particle traveling in the center path 1909 provides the strongest signal, with the integration under the curve equaling, for example, 1.0. In contrast, the signals obtained from the top and bottom paths 1907 and 1911 , respectively, show weaker signals with the integration of both curves equaling, for example, 0.5. Thus identical particles traveling through different parts of the fluorescence inducing beam produce different amounts of fluorescence. This nonuniformity in signals confuses the discrimination of different types of particles. For example a big particle traveling through the edge of the fluorescence inducing beam may generate as much fluorescence signal as a small particle traveling through the center of the fluorescence inducing beam
Block 1913 represents the pattern beam 1915 , and the particle paths 1917 a - c , as was previously described in the system shown in FIG. 2 . Using the information from the previously described particle detection system, it may be possible to determine where the particle is traveling in the fluorescent beam. As shown in region 1932 the fluorescent beam 1903 may be superimposed with the particle beam 1915 , thus, the two obtained measurements may be combined in order to find the exact location of the particle traveling through the fluorescent beam. Using the knowledge of the particle position, a normalization (or correction) factor may be compiled, such that the normalization factor may be multiplied by the weaker signals 1907 and 1911 . Therefore, the weaker signals may be normalized so that their integration values equals 1, resulting in a stronger signal reading as shown in the updated signals 1927 , 1929 and 1931 . Such a calculation may be obtained from a calculation unit 1925 . This normalization removes the variation in fluorescence signals due to particle position and allows the remaining variations to be interpreted as variations in particle characteristics.
While this invention has been particularly shown and described with references to example embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims. | Aerosol and hydrosol particle detection systems without knowledge of a location and velocity of a particle passing through a volume of space, are less efficient than if knowledge of the particle location is known.
An embodiment of a particle position detection system capable of determining an exact location of a particle in a fluid stream is discussed. The detection system may employ a patterned illuminating beam, such that once a particle passes through the patterned illuminating beam, a light scattering is produced. The light scattering defines a temporal profile that contains measurement information indicative of an exact particle location.
However, knowledge of the exact particle location has several advantages. These advantages include correction of systematic particle measurement errors due to variability of the particle position within the sample volume, targeting of particles based on position, capture of particles based on position, reduced system energy consumption and reduced system complexity. | 66,741 |
This application is a 371 of PCT International Application No. PCT/AU97/00294, filed May 13, 1997.
FIELD OF THE INVENTION
The present invention relates to novel molecules which may be advantageously incorporated in membrane based biosensors.
BACKGROUND OF THE INVENTION
Previous patents such as WO 92/17788, U.S. Pat. No. 5,204,239 and WO 93/21528 (the disclosures of which are incorporated herein by reference) have described how functional biosensor bilayer or monolayer lipid membranes may be formed on a metal substrate such that a functioning ionic reservoir is formed between the metal surface and the lipid membrane. The inner leaflet of the membrane, or in the case of the monolayer membrane the whole membrane is typically assembled using molecules that comprise within the same molecule a hydrophobic group linked to a hydrophilic group onto which is attached an attachment group such as a disulfide or thiol group capable of attaching the molecule to an electrode. Furthermore, it has been disclosed in WO 94/07593 (the disclosure of which is also included herein by reference) that in order to provide improved reservoir characteristics and fluidity characteristics of the membrane a small spacer molecule, such as the disulfide of mercaptoacetic acid, should be incorporated between the reservoir molecules that had been adsorbed onto the metal surface.
The present inventors have now determined that if the functionality of the small spacer molecule is covalently incorporated into the reservoir molecules described previously, such that a single molecule is formed, then improvements in stability and reproducibility of the membrane formation, as well as improved ionophore conduction can be achieved. Additionally the manufacture of the membrane is simplified as fewer components are required.
SUMMARY OF THE INVENTION
Accordingly, in a first aspect, the present invention consists in a linker lipid for use in attaching a membrane including a plurality of ionophores to an electrode and providing a space between the membrane and the electrode in which the membrane is either in part or totally made up of the linker lipid, the linker lipid comprising within the same molecule a hydrophobic region capable of spanning the membrane, an attachment group used to attach the molecule to an electrode surface, a hydrophilic region intermediate said hydrophobic region and the attachment group, and a polar head group region attached to the hydrophobic region at a site remote from the hydrophilic region wherein said attachment group has a cross sectional area that is at least two times the cross sectional area of the hydrophilic region.
It is preferred that the head group, hydrophobic region, and hydrophilic region are as described previously in WO 92/17788 and WO 94/07593. The linker lipid in this case may be wholly synthetic or derived from naturally occurring membrane spanning lipids or archaebacterial lipids.
The hydrophilic region of the linker lipid is preferably a long chain hydrophilic compound. The hydrophilic region of the linker lipid may be composed of oligo/poly ethers, oligo/poly peptides, oligo/poly amides, oligo/poly amines, oligo/poly esters, oligo/poly saccharides, polyols, multiple charged groups (positive and/or negative), electroactive species or combinations thereof. The main requirement of the hydrophilic region of the linker lipid is that it allows the diffusion of ions through the ionophores provided in the membrane. This is achieved by the placement of suitable ion and/or water binding sites along or within the length of the long chain that makes up the reservoir region.
In a preferred embodiment of the invention the hydrophilic region consists of an oligoethylene oxide group. The oligoethylene oxide group may consist of four to twenty ethylene oxide units.
In a further preferred embodiment the hydrophilic region consists of a subunit of tetraethylene glycol attached to succinic acid. This tetraethylene glycol/succinic acid subunit may be repeated 1-4 times.
In a further preferred embodiment the hydrophilic region is formed by group transfer or anionic polymerisation of suitable monomers.
In a further preferred embodiment the hydrophilic region consists of mercaptoethanol, succinic acid, 1,4-diesterified 1,2,3,4-butanetetraol and succinic acid subunits. The succinic acid/1,4-diesterified 1,2,3,4-butanetetraol may be repeated 1-4 times.
In yet another embodiment the hydrophilic region may consist of an oligopropylene glycol of between 1 to 20 propylene glycol units in length. It is further preferred that the hydrophilic region consists oligopropylene glycols of between 2 and 8 propylene glycol units that are functionalised at each end with an N-alkyl amine functionality and that may be joined together via acid units forming tertiary amides.
It is further preferred that the hydrophilic region consists of oligoethylene glycols of between 2 and 10 ethylene glycol units that are functionalised at each end with an N-alkyl amine functionality and that may be joined together via acid units forming tertiary amides.
In a preferred embodiment of the present invention the head group of the linker lipid comprises a receptor reactive with an analyte or a group capable of attaching to a protein receptor.
In a preferred embodiment, the head group comprises a biotin or biotin derivative capable of complexing streptavidin, avidin or one of the common biotin binding proteins.
In a further preferred embodiment the biotin group is linked to the linker lipid via 1 to 8 aminocaproyl groups.
In a further preferred embodiment two biotin groups are attached to the linker lipid such that both biotin groups are capable of complexing a single avidin or streptavidin molecule so as to increase the overall complexing ability and strength of the linker lipid to the avidin or streptavidin.
In a further preferred embodiment of the present invention the hydrophobic region of the membrane spanning lipid comprises a hydrocarbon backbone of between 20-60 angstroms in length with sites of attachment at either end of the hydrocarbon backbone to which are attached at least two hydrocarbon side chains such as phytanyl chains.
In a further preferred embodiment of the present invention the hydrophobic region of the membrane spanning lipid comprises a hydrocarbon backbone of between 20-60 angstroms in length with sites of attachment at either end of the hydrocarbon backbone to which are attached at one end zero or one hydrocarbon sidechain and at least two to four hydrocarbon sidechains at the other end.
The hydrocarbon backbone may comprise a straight methylene chain hydrocarbon, or a hydrocarbon chain optionally substituted with additional groups selected from alkyl, aryl, ether and amine groups, or may comprise two shorter hydrocarbon chains that have been joined via ether, amine, or biphenyl ether groups. Those skilled in the art will appreciate that other functionalities that can link two hydrocarbon chains may also be employed.
It is preferred that the means by which the hydrocarbon chains are attached to the hydrocarbon backbone is via a polyhydroxylated hydrocarbon containing from 3 to 20 hydroxyl groups.
It is further preferred that the means by which the hydrocarbon sidechains are attached to the hydrocarbon backbone is via glycerol, glutamic acid, erythritol, threitol or pentaerythritol groups.
It is preferred that the length of the hydrocarbon sidechains are approximately half the total length of the hydrocarbon backbone.
It is further preferred that the hydrocarbon sidechains are phytanyl chains.
It is further preferred that the hydrocarbon sidechains are mono- or per-methylated hydrocarbon chains or a hydrocarbon chain optionally substituted with additional groups selected from alkyl, aryl, ether and amine groups.
It is preferred that for the case of the electrode material being a gold, platinum, palladium, silver or other coinage metal substrate or combination thereof, the attachment region includes sulfur containing groups such as thiols, disulfides, sulfides thiocyanates. However as previously described, other groups such as organosilanes that form strong attachment to a variety of conductive substrates may also be used.
In the case where the hydrophilic region of the linker lipid is a single chain it is preferred that the attachment region of the molecule is an array containing two to twenty sulfur atoms.
It is further preferred that the attachment region includes between one to three disulfide groups.
Further preferred that the attachment region includes up to 6 thiol groups.
It is further preferred that the attachment group has the following structure:
X—Y[(CH 2 ) n SR] m
where X is either a carbon, nitrogen or oxygen to which the hydrophilic region is attached, Y is a carbon or if X is a carbon Y may be a nitrogen, n is between 1 to 6, m is between 1 to 3 if Y is a carbon and between 1 to 2 if Y is a nitrogen, and R is a small group such as any of the following —SH, —SCH 2 Ph, —SCH 2 CO 2 H, —SCH 2 CH 2 CO 2 H, —SCH 2 CH 2 OH, —SCH 2 CH 2 CH 2 OH, —SCH 3 , —SCH 2 CH 3 , —SCH 2 CH 2 CH 3 , —SCH2CO 2 CH 3 , —SCH 2 CO 2 CH 2 CH 3 , an a containing between 1 and 4 carbon atoms, or an aryl group.
In a further preferred embodiment of the present invention the attachment group has the following structure:
X—Y[(CH 2 ) n Z(CH 2 ) p SR] m
where X is either a carbon, nitrogen or oxygen to which the hydrophilic region is attached, Y is a carbon or if X is a carbon Y may be a nitrogen, m is between 1 to 3 if Y is a carbon and between 1 to 2 if Y is a nitrogen, where Z is O, NH, NR 1 , an amide or ketone, and where n is between 1 and 5 and p is between 2 and 5, unless Y is N, in which case n is between 2 and 5, and where R 1 is an alkyl chain containing between 1 and 4 carbon atoms, and R is a small group such as any of the following —SH, —SCH 2 Ph, —SCH 2 CO 2 H, —SCH 2 CH 2 CO 2 H, —SCH 2 CH 2 OH, —SCH 2 CH 2 CH 2 OH, —SCH 3 , —SCH 2 CH 3 , —SCH 2 CH 2 CH 3 , —SCH2CO 2 CH 3 , —SCH 2 CO 2 CH 2 CH 3 , an alkyl chain containing between 1 and 4 carbon atoms, or an aryl group.
It is further prefered that the attachment group is thiooctic acid or bis-thiooctic acid derivative.
It is further preferred that the attachment group is the cyclic oxidised form of dithiothreitol.
It is further preferred that the attachment group contains one to three bis(4-hydroxymethyl)-1,2-dithiacyclopentane groups.
It is further preferred that the attachment group contains a bis(4-hydroxymethyl)-1,2-dithiacyclopentane groups where the hydrophilic reservoir is attached via one of the 4-hydroxymethyl moieties of the bis(4-hydroxymethyl)-1,2-dithiacyclopentane and where the other 4-hydroxymethyl moiety may be the hydroxy functionality or may have been further functionalised to a methyl ether, ethyl ether, propyl ether, acetate, or succinate, or a group of the formula (CH 2 ) n COZ where n is 0 to 4, and Z is OR, or NR 1 R 2 , where R, R 1 and R 2 are independently hydrogen or alkyl chains containing between 1 and 4 carbon atoms.
It is further preferred that the attachment group contains a bis(4-hydroxymethyl)-1,2-dithiacyclopentane groups where the hydrophilic reservoir is attached via one of the 4-hydroxymethyl moieties of the bis(4-hydroxymethyl)-1,2-dithiacyclopentane and where the other 4-hydroxymethyl moiety may be linked to between one and three other bis(4-hydroxymethyl)-1,2-dithiacyclopentane groups.
It is further preferred that the linking group be ethyleneoxy or diethyleneoxy.
It is further preferred that the attachment group contains one to three dithiothreitol groups.
It is further preferred that the attachment group contains a trans-4,5-dihydroxy-1,2-dithiacyclohexane groups where the hydrophilic reservoir is attached via one of the 4,5-hydroxy moieties of the trans-4,5-dihydroxy-1,2-dithiacyclohexane and where the other 4,5-hydroxy moiety may be the hydroxy functionality or may have been further functionalised to a methyl ether, ethyl ether, propyl ether, acetate, or succinate, or a group of the formula (CH 2 ) n COZ where n is 0 to 4, and Z is OR, or NR 1 R 2 , where R, R 1 and R 2 are independently hydrogen or alkyl chains containing between 1 and 4 carbon atoms.
It is further preferred that the attachment group contains a trans-4,5-dihydroxy-1,2-dithiacyclohexane groups where the hydrophilic reservoir is attached via one of the 4,5-hydroxy moieties of the trans-4,5-dihydroxy-1,2-dithiacyclohexane and where the other 4,5-hydroxy moiety may be linked to between one and three other trans-4,5-dihydroxy-1,2-dithiacyclohexane groups.
In a further preferred embodiment the cross sectional area of the hydrophobic region is similar to the cross sectional area of the attachment group as shown schematically in FIG. 1 .
In a second aspect, the present invention consists in a linker lipid for use in attaching a bilayer membrane including a plurality of ionophores to an electrode and providing a space between the membrane and the electrode in which the membrane layer proximate the electrode is either in part or totally made up of the linker lipid, the linker lipid comprising within the same molecule a hydrophobic region which spans half the membrane, an attachment group used to attach the molecule to an electrode surface, and a hydrophilic region intermediate said hydrophobic region and the attachment group, wherein said attachment group has a cross sectional area that is at least two times the cross sectional area of the hydrophilic region.
It is preferred that the hydrophobic region is a phytanyl chain.
It is further preferred that the hydrophobic region is a mono- or per-methylated hydrocarbon chain or a hydrocarbon chain optionally substituted with additional groups selected from alkyl, aryl, ether and amine groups.
It is preferred that the hydrophobic region is comprised of a polyether containing hydrocarbon chains, such as phytanyl, attached to polyol.
It is further preferred that the hydrophobic region comprises 2 to 4 hydrocarbon chains such as phytanyl chains.
It is further preferred that the hydrophobic region comprise a diphytanyl glyceryl ether.
It is further preferred that the hydrophobic region comprise a triphytanyl pentaerythrityl ether.
It is further preferred that the hydrophobic region comprise a triphytanyl threityl ether.
It is further preferred that the hydrophobic region comprise a triphytanyl erythritol ether.
It is preferred that for the case of the electrode material being a gold, platinum, palladium, silver or other coinage metal substrate or combination thereof, the attachment region includes sulfur containing groups such as thiols, disulfides, sulfides thiocyanates. However as previously described, other groups such as organosilanes that form strong attachment to a variety of conductive substrates may also be used.
In the case where the hydrophilic region of the linker lipid is a single chain it is preferred that the attachment region of the molecule is an array containing two to twenty sulfur atoms.
It is further preferred that the attachment region includes between one to three disulfide groups.
Further preferred that the attachment region includes up to 6 thiol groups.
It is further preferred that the attachment group has the following structure:
X—Y[(CH 2 ) n SR] m
where X is either a carbon, nitrogen or oxygen to which the hydrophilic region is attached, Y is a carbon or if X is a carbon Y may be a nitrogen, n is between 1 to 6, m is between 1 to 3 if Y is a carbon and between 1 to 2 if Y is a nitrogen, and R is a small group such as any of the following —SH, —SCH 2 Ph, —SCH 2 CO 2 H, —SCH 2 CH 2 CO 2 H, —SCH 2 CH 2 OH, —SCH 2 CH 2 CH 2 OH, —SCH 3 , —SCH 2 CH 3 , —SCH 2 CH 2 CH 3 , —SCH2CO 2 CH 3 , —SCH 2 CO 2 CH 2 CH 3 , an alkyl chain containing between 1 and 4 carbon atoms, or an aryl group.
In a further preferred embodiment of the present invention the attachment group has the following structure:
X—Y[(CH 2 ) n Z(CH 2 ) p SR] m
where X is either a carbon, nitrogen or oxygen to which the hydrophilic region is attached, Y is a carbon or if X is a carbon Y may be a nitrogen, m is between 1 to 3 if Y is a carbon and between 1 to 2 if Y is a nitrogen, where Z is O, NH, NR 1 , an amide or ketone, and where n is between 1 and 5 and p is between 2 and 5, unless Y is N, in which case n is between 2 and 5, and where R 1 is an alkyl chain containing between 1 and 4 carbon atoms, and R is a small group such as any of the following —SH, —SCH 2 Ph, —SCH 2 CO 2 H, —SCH 2 CH 2 CO 2 H, —SCH 2 CH 2 OH, —SCH 2 CH 2 CH 2 OH, —SCH 3 , —SCH 2 CH 3 , —SCH 2 CH 2 CH 3 , —SCH2CO 2 CH 3 , —SCH 2 CO 2 CH 2 CH 3 , an alkyl chain containing between 1 and 4 carbon atoms, or an aryl group.
It is further prefered that the attachment group is thiooctic acid or bis-thiooctic acid derivative.
It is further preferred that the attachment group is the cyclic oxidised form of dithiothreitol.
It is further preferred that the attachment group contains one to three bis(4-hydroxymethyl)-1,2-dithiacyclopentane groups.
It is further preferred that the attachment group contains a bis(4-hydroxymethyl)-1,2-dithiacyclopentane groups where the hydrophilic region is attached via one of the 4-hydroxymethyl moieties of the bis(4-hydroxymethyl)-1,2-dithiacyclopentane and where the other 4-hydroxymethyl moiety may be the hydroxy functionality or may have been further functionalised to a methyl ether, ethyl ether, propyl ether, acetate, or succinate. or a group of the formula (CH 2 ) n COZ where n is 0 to 4, and Z is OR, or NR 1 R 2 , where R, R 1 and R 2 are independently hydrogen or alkyl chains containing between 1 and 4 carbon atoms.
It is further preferred that the attachment group contains a bis(4-hydroxymethyl)-1,2-dithiacyclopentane groups where the hydrophilic region is attached via one of the 4-hydroxymethyl moieties of the bis(4-hydroxymethyl)-1,2-dithiacyclopentane and where the other 4-hydroxymethyl moiety may be linked to between one and three other bis(4-hydroxymethyl)-1,2-dithiacyclopentane groups.
It is further preferred that the linking group be ethyleneoxy or diethyleneoxy.
It is further preferred that the attachment group contains one to three dithiothreitol groups.
It is further preferred that the attachment group contains a trans-4,5-dihydroxy-1,2-dithiacyclohexane groups where the hydrophilic region is attached via one of the 4,5-hydroxy moieties of the trans-4,5-dihydroxy-1,2-dithiacyclohexane and where the other 4,5-hydroxy moiety may be the hydroxy functionality or may have been further functionalised to a methyl ether, ethyl ether, propyl ether, acetate, or succinate, or a group of the formula (CH 2 ) n COZ where n is 0 to 4, and Z is OR, or NR 1 R 2 , where R, R 1 and R 2 are independently hydrogen or alkyl chains containing between 1 and 4 carbon atoms.
It is further preferred that the attachment group contains a trans-4,5-dihydroxy-1,2-dithiacyclohexane groups where the hydrophilic region is attached via one of the 4,5-hydroxy moieties of the trans-4,5-dihydroxy-1,2-dithiacyclohexane and where the other 4,5-hydroxy moiety may be linked to between one and three other trans-4,5-dihydroxy-1,2-dithiacyclohexane groups.
Ionophore ion channels such as gramicidin generally need to assume a particular conformation in order to form conducting channels. Gramicidin A for instance is thought to assume a beta-helical structure in its conducting form. It is thought that if there is sufficient crowding of the linker gramicidin by linker lipid molecules during the deposition of the inner sulfur/gold lipid layer, then this crowding may adversely affect the ability of the ion channel to assume its proper conformation and hence reduce its capability of forming conducting channels. Previously this crowding was thought to be minimised by the use of small sulfur containing spacer molecules. A more controllable method is to increase the cross sectional area of the attachment group such that its cross sectional area is comparable to the cross sectional area of the ion channel.
Hence, in a third aspect, the present invention consists in a linker ion channel for use in a bilayer or monolayer membrane based biosensor including an electrode, said linker ion channel comprising within the same molecule a hydrophobic ion channel which spans at least half the membrane, an attachment group to attach the linker ion channel to the electrode surface, a hydrophilic region intermediate said hydrophobic ion channel and the attachment group, wherein said attachment group has a cross sectional area that is at least the cross sectional area of the hydrophobic ion channel.
It is preferred that the ion channel is gramicidin or one of its derivatives.
It is further preferred that the ion channel is a synthetic ion channel.
It is preferred that for the case of the electrode material being a gold, platinum, palladium, silver or other coinage metal substrate or combination thereof, the attachment region includes sulfur containing groups such as thiols, disulfides, sulfides thiocyanates. However as previously described, other groups such as organosilanes that form strong attachment to a variety of conductive substrates may also be used.
In the case where the hydrophilic region of the linker lipid is a single chain it is preferred that the attachment region of the molecule is an array containing two to twenty sulfur atoms.
It is further preferred that the attachment region includes between one to three disulfide groups.
Further preferred that the attachment region includes up to 6 thiol groups.
It is further preferred that the attachment group has the following structure:
X—Y[(CH 2 ) n SR] m
where X is either a carbon, nitrogen or oxygen to which the hydrophilic region is attached, Y is a carbon or if X is a carbon Y may be a nitrogen, n is between 1 to 6, m is between 1 to 3 if Y is a carbon and between 1 to 2 if Y is a nitrogen, and R is a small group such as any of the following —SH, —SCH 2 Ph, —SCH 2 CO 2 H, —SCH 2 CH 2 CO 2 H, —SCH 2 CH 2 OH, —SCH 2 CH 2 CH 2 OH, —SCH 3 , —SCH 2 CH 3 , —SCH 2 CH 2 CH 3 , —SCH2CO 2 CH 3 , —SCH 2 CO 2 CH 2 CH 3 , an alkyl chain containing between 1 and 4 carbon atoms, or an aryl group.
In a further preferred embodiment of the present invention the attachment group has the following structure:
X—Y[(CH 2 ) n Z(CH 2 ) p SR] m
where X is either a carbon, nitrogen or oxygen to which the hydrophilic region is attached, Y is a carbon or if X is a carbon Y may be a nitrogen, m is between 1 to 3 if Y is a carbon and between 1 to 2 if Y is a nitrogen, where Z is O, NH, NR 1 , an amide or ketone, and where n is between 1 and 5 and p is between 2 and 5, unless Y is N, in which case n is between 2 and 5, and where R 1 is. an alkyl chain containing between 1 and 4 carbon atoms, and R is a small group such as any of the following —SH, —SCH 2 Ph, —SCH 2 CO 2 H, —SCH 2 CH 2 CO 2 H, —SCH 2 CH 2 OH, —SCH 2 CH 2 CH 2 OH, —SCH 3 , —SCH 2 CH 3 , —SCH 2 CH 2 CH 3 , —SCH2CO 2 CH 3 , —SCH 2 CO 2 CH 2 CH 3 , an alkyl chain containing between 1 and 4 carbon atoms, or an aryl group.
In a further preferred embodiment of the present invention the attachment group has the following structure:
P—Q[(CH 2 ) n T(CH 2 ) p W] m
where P either a carbon, nitrogen or oxygen to which the hydrophilic reservoir region is attached, Q is a carbon or if P is a carbon Q may be a nitrogen, n is between 1 to 6, m is between 1 to 3 if Q is a carbon and between 1 to 2 if Q is a nitrogen, T is O, NH, NR 1 , an amide or ketone, and where n is between 1 and 5 and p is between 2 and 5, unless Q is N, in which case n is between 2 and 5, and where R 1 is an alkyl chain containing between 1 and 4 carbon atoms, and W is a group of the formula:
X—Y[(CH 2 ) n Z(CH 2 ) p SR] m
where X is either a carbon, nitrogen or oxygen, Y is a carbon or an alkyl chain of 1-4 carbons or if X is a carbon Y may be a nitrogen, m is between 1 to 3 if Y is a carbon and between 1 to 2 if Y is a nitrogen, where Z is a bond, O, NH, NR 1 , an amide or ketone, and where n is between 1 and 5 and p is between 2 and 5, unless Y is N, in which case n is between 2 and 5, and where R 1 is an alkyl chain containing between 1 and 4 carbon atoms, and R is a small group such as any of the following —SH, —SCH 2 Ph, —SCH 2 CO 2 H, —SCH 2 CH 2 CO 2 H, —SCH 2 CH 2 OH, —SCH 2 CH 2 CH 2 OH, —SCH 3 , —SCH 2 CH 3 , —SCH 2 CH 2 CH 3 , —SCH2CO 2 CH 3 , —SCH 2 CO 2 CH 2 CH 3 , an alkyl chain containing between 1 and 4 carbon atoms, or an aryl group.
It is further prefered that the attachment group is thiooctic acid or bis-thiooctic acid derivative.
It is further preferred that the attachment group is the cyclic oxidised form of dithiothreitol.
It is further preferred that the attachment group contains one to three bis(4-hydroxymethyl)-1,2-dithiacyclopentane groups.
It is further preferred that the attachment group contains a bis(4-hydroxymethyl)-1,2-dithiacyclopentane groups where the hydrophilic region is attached via one of the 4-hydroxymethyl moieties of the bis(4-hydroxymethyl)-1,2-dithiacyclopentane and where the other 4-hydroxymethyl moiety may be the hydroxy functionality or may have been further functionalised to a methyl ether, ethyl ether, propyl ether, acetate, or succinate, or a group of the formula (CH 2 ) n COZ where n is 0 to 4, and Z is OR, or NR 1 R 2 , where R, R 1 and R 2 are independently hydrogen or alkyl chains containing between 1 and 4 carbon atoms.
It is further preferred that the attachment group contains a bis(4-hydroxymethyl)-1,2-dithiacyclopentane groups where the hydrophilic region is attached via one of the 4-hydroxymethyl moieties of the bis(4-hydroxymethyl)-1,2-dithiacyclopentane and where the other 4-hydroxymethyl moiety may be linked to between one and three other bis(4-hydroxymethyl)-1,2-dithiacyclopentane groups.
It is further preferred that the linking group be ethyleneoxy or diethyleneoxy.
It is further preferred that the attachment group contains one to three dithiothreitol groups.
It is further preferred that the attachment group contains a trans-4,5-dihydroxy-1,2-dithiacyclohexane groups where the hydrophilic region is attached via one of the 4,5-hydroxy moieties of the trans-4,5-dihydroxy-1,2-dithiacyclohexane and where the other 4,5-hydroxy moiety may be the hydroxy functionality or may have been further functionalised to a methyl ether, ethyl ether, propyl ether, acetate, or succinate, or a group of the formula (CH 2 ) n COZ where n is 0 to 4, and Z is OR, or NR 1 R 2 , where R, R 1 and R 2 are independently hydrogen or alkyl chains containing between 1 and 4 carbon atoms.
It is further preferred that the attachment group contains a trans-4,5-dihydroxy-1,2-dithiacyclohexane groups where the hydrophilic region is attached via one of the 4,5-hydroxy moieties of the trans-4,5-dihydroxy-1,2-dithiacyclohexane and where the other 4,5-hydroxy moiety may be linked to between one and three other trans-4,5-dihydroxy-1,2-dithiacyclohexane groups.
Sulfur containing compounds can be prepared by conventional literature procedures. Cyclic disulfides can also be prepared by conventional literature procedures, however, it is presently preferred that cyclic disulfides are prepared by the cyclisation of a α,ω-disubstituted thiocyanates by treatment with a source of fluoride ion. It is further preferred that the fluoride ion source is tetrabutylammonium fluoride. The reaction is conducted in an organic solvent or mixture of solvents, at a temperature between −70° and 100° C. It is further preferred that the reaction is conducted in aqueous tetrahydrofuran between 0° and 50° C.
Accordingly in a fourth aspect the present invention consists in a method of producing cyclic disulfides, the method comprising reacting an α,ω-disubstituted thiocyanate with a source of fluoride ion.
In a fifth aspect the present invention consists in linker lipids described in the first aspect of the invention which in addition have an ionophore covalently attached to the hydrophobic region of the linker lipid via at least one tethering chain which is long enough such that the attached ionophore may traverse the membrane in such a way that it is still able to transport ions across the membrane.
Typical ionophores may be natural, semi-synthetic or wholly synthetic ionophores such as valinomycin, nonactin, crown ether derivatives, podands, coronands, cryptands, gramicidin.
In a sixth aspect the present invention consists in a membrane formed exclusively from linker lipids of the first aspect of the invention and fourth aspect of the present invention to which are tethered ionophores.
In a seventh aspect the present invention consists in a membrane formed from a plurality of linker lipids according to the first aspect and a plurality of linker lipids according to the second aspect of the invention and additional lipids and ion channels so as to form a membrane that has the similar thickness to a normal bilayer membrane structure.
It is further preferred that the ion channel added to the membrane is a gramicidin derivative that is capable of being linked to a protein such as streptavidin or an antibody or antibody fragment or other receptor molecule.
In a preferred embodiment of this aspect of the present invention the membrane also includes a plurality of linker ion channels according to the third aspect of the invention.
As will be appreciated by those skilled in this field that the membranes of the present invention may include additional lipid. In these instances it is preferred that the additional lipid is a mixture of diphytanyl ether phosphatidyl choline and glycerol diphytanyl ether in a ratio of between 9:1 to 6:4.
Those skilled in the art will also appreciate that where molecules can exist as stereoisomers, that any of the individual stereoisomers, or mixtures thereof, may be employed. In addition, where amines are employed it will be appreciated that common salts of the amines could also be employed.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the nature of the present invention may be more clearly understood preferred forms thereof will now be described with reference to the following examples and Figures in which:
FIG. 1 is a schematic representation of an embodiment of the present invention;
FIG. 2 shows linker lipid A;
FIG. 3 shows linker gramicidin B;
FIG. 4 shows membrane spanning lipid; and
FIG. 5 shows biotinylated gramicidin E
DETAILED DESCRIPTION OF THE INVENTION
Chemical Syntheses
A solution of phytol (49.3 g, 166 mmol) in ethanol (250 ml) was reduced with hydrogen gas at atmospheric pressure over Raney nickel for 3 days. The catalyst was removed by filtration through Celite® and the filtrate concentrated under reduced pressure to give phytanol (49.3 g, 100%). 1 H-n.m.r. (CDCl 3 ) δ0.8-0.95 (m, 15H), 1.0-1.75 (m, 24H), 3.65-3.75 (m, 2H). 13 C-n.m.r. (CDCl 3 ) δ19.67 (3×Me), 22.60 (Me), 22.69 (Me), 24.36 (CH 2 ), 24.45 (CH 2 ), 24.78 (CH 2 ), 27.95 (CH), 29.50 (CH), 32.76 (2×CH), 37.28-37.43 (m, 5×CH 2 ), 39.35 (CH 2 ), 39.73 and 40.05 (together CH 2 ), 61.18 (CH 2 ).
A mixture of phytanol (5.98 g, 20 mmol) and succinic anhydride (6.0 g) were stirred in dry pyridine (40 ml) under nitrogen for 4 days at room temperature. The mixture was poured into ice-cold hydrochloric acid (2M, 110 ml), the pH adjusted to approximately 3 with additional hydrochloric acid (2M, 50 ml), and the solution extracted with dichloromethane (3×150 ml). The combined organic extracts were washed with hydrochloric acid (1M, 120 ml) and water (200 ml). The final water extract was re-extracted with dichloromethane (100 ml). The combined organic layers were dried (Na 2 SO 4 ), filtered and the solvent removed under reduced pressure. Phytanyl hemisuccinate was obtained as a colourless oil (7.77 g. 97%). 1 H-n.m.r. (CDCl 3 ) δ0.8-0.95 (m, 15H), 0.95-1.80 (m, 24H), 2.55-2.75 (m, 4H), 4.05-4.20 (m, 2H). 13 C-n.m.r. (CDCl 3 ) δ20.1, 20.2, 20.29, 120.36, 20.43, 23.3, 23.4, 25.0, 25.1, 25.5, 28.6, 29.6, 29.7, 30.5, 33.4, 36.1, 36.2, 37.8-38.2, 40.0. 64.2, 172.9, 179.1.
Phytanyl hemisuccinate (0.19 g), tetraethylene glycol (463 mg), DCC (120 mg, 0.16 mmol), DMAP (19 mg, 0.16 mmol), and DMAP.HCl (25 mg) in chloroform (2 ml) were stirred under nitrogen for 70 hours at room temperature. The suspension was filtered, the precipitate washed with dichloromethane, and the combined filtrates were concentrated to dryness under reduced pressure. The residue was purified by flash chromatography (ethyl acetate as eluant) to yield phytanyl (teraethylene glycyl) succinate in 186 mg (68%). 1 H-n.m.r. (CDCl 3 ) δ0.84 (m, 15H), 0.90-1.75 (m, 24H), 2.63 (m, 4H), 3.55-3.75 (m, 14H), 4.09 (m, 2H), 4.28 (m, 2H).
To a solution of tripropyleneglycol (prepared following K. Burgess, M. J. Ohlmeyer., J. Org. Chem., 1988, 53, 5179-5181) (2.05 g) and phytanyl hemisuccinate (850 mg) in dry dichloromethane (10 ml), 1-cyclohexyl-3-(2-morpholinoethyl)carbodiimide metho-p-toluenesulfonate (morpho-CDI) (1.08 g), DMAP.HCl (112.5 mg) DMAP (86 mg, 0.71 mmol) was added and the mixture stirred at room temperature for 48 h. The suspension was filtered and the residue washed with dichloromethane (50 ml). The filtrate evaporated and the residue chromatographed (ethyl acetate:light petroleum 1:1) to give the product (980 mg, 80%) 1 H nmr (CDCl 3 ) δ0.81-1.27 (m, 39H, phytanyl H), 1.79-1.91 (m, 6H, CH 2 —CH 2 —CH 2 ), 2.47 (t, 2H, CH 2 —SS—Ph), 2.61 (s, 6H, CO—(CH 2 ) 2 —CO), 3.44-3.54 (m, 4H, CH 2 —O), 3.61 (t, 2H, CH 2 —O), 3.76 (t, 2H, CH 2 —O), 4.11 (t, 2H, CH 2 —O—CO), 4.17 (t, 2H, CH 2 —O—CO). m/z 573 (M+H) + .
Hexaethylene glycol (2.908 g), morpho-CDI (1.070 g), DMAP (0.086 g) and DMAP hydrochloride (0.112 g) were dissolved in dry dichloromethane (9 ml) at room temperature under nitrogen. Phytanyl hemisuccinate (0.840 g) was added dropwise over 10 min. to the stirred solution and the mixture stirred for 4 days. The suspension was filtered and the solid urea washed with dichloromethane. The filtrate was washed with water (20 ml), 1M HCl (20 ml) and brine (20 ml) and the solvent evaporated to give a colourless oil (1.30 g, 93%). Chromatography on silica gel with ethyl acetate as eluant yielded the pure title compound (0.90 g, 64%) as a colourless oil (Found, C, 65.66; H,10.84. C 36 H 70 O 10 requires C, 65.66; H,10.64%). 1 H nmr (CDCl 3 ) δ0.75-0.91 (m, 15H, 5×phytanyl Me), 0.91-1.72 (m, 24H, phytanyl), 2.62 (m, 4H, 2×succinate CH 2 ), 3.04 (s, 1H, OH), 3.56-3.73 (m, 22H, 11×HEG CH 2 ), 4.10 (m, 2H, phytanyl OCH 2 ) and 4.23 (m, 2H, HEG CH 2 OCO); δ C (CDCl 3 ) 19.41-19.70 (m), 22.59, 22.67, 24.26, 24.42, 24.75, 27.92, 29.01, 29.07, 29.81, 32.73, 35.40, 35.48, 37.23,7.34, 9.32, 61.67, 63.35, 63.79, 69.12, 70.26, 70.51, 72.48, and 172.29; m/z (M + +1) 663.
17-Hydroxy-3,6,9,12,15-pentaoxa-heptadecan-1-yl phytanyl succinate (0.80 g) and succinic anhydride (0.361 g) were stirred in dry pyridine (4.5 ml) at room temperature under nitrogen for 45 hours. The mixture was poured into ice-cold hydrochloric acid (2M, 20 ml) and adjusted to pH 3 with further cold acid, extracted with dichloromethane (3×130 ml) and the combined organic layers washed with brine (150 ml), dried (Na 2 SO 4 ), filtered and the solvent removed to give the title compound (0.84 g, 91%) as a colourless oil which was of high purity by TLC and 1 H NMR spectroscopy (Found, C, 62.43; H; 10.15. C 40 H 74 O 13 requires C, 62.97; H, 9.78%). 1 H nmr (CDCl 3 ) δ0.75-0.94 (m, 15H, 5×phytanyl Me), 0.94-1.75 (m, 24H, phytanyl), 2.62 (m, 8H, 4×succinate CH 2 ), 3.55-3.75 (m, 20H, 10×HEG CH 2 ), 4.12 (m, 2H, phytanyl CH 2 ) and 4.25 (m, 4H, HEG CH 2 OCO).
((3,6,9,12,15-Pentaoxa-heptadecanyl) diphytanylglyceryl succinate) hemisuccinate was prepared following the procedure for the synthesis of ((3,6,9,12,15-pentaoxa-heptadecanyl) phytanyl succinate) hemisuccinate, though replacing phytanol with (diphytanyl)glycerol. 1 H nmr (CDCl 3 ) δ0.75-0.92 (m, 30H, 10×phytanyl Me), 0.92-1.72 (m, 48H, phytanyl), 2.65 (broad s, 8H, 4×succinate CH 2 ), 3.40-3.72 (m, 27H, 13×CH 2 O and CHO), 4.06-4.32 (m, 6H, 3×CH 2 OCO).
p-Toluenesulfonyl chloride (17.1 g) was added portionwise to triethylene glycol (15 g) in pyridine (600 ml) at 0° C. The solution was allowed to warm to room temperature and stirring continued for 16 h. The solvent was removed under reduced pressure to approximately 50 ml and the residue diluted with hydrochloric acid (100 ml, 3M), extracted with dichloromethane (3×100 ml), washed with brine (150 ml), dried (Na 2 SO 4 ), and the solvent removed under reduced pressure. The resulting pale orange oil was purified by flash chromatography (ethyl acetate) to give triethylene glycol mono tosylate from the most polar fractions as a clear oil (6.94 g, 23%). 1 H nmr (CDCl 3 ) δ2.44 (s, 3H), 2.56 (br s, 1H OH), 3.56-3.73 (m, 10H), 4.16 (m, 2H), 7.38 and 7.78 (AB quartet, 2H each); 13 C nmr (CDCl 3 ) δ21.33, 42.52, 61.25, 68.31, 69.00, 69.86, 70.36, 72.25, 127.64, 129.63, 144.71; m/z (CI) 305 (M+H) + .
Imidazole (1.68 g, 24.6 mmol) and t-butyldimethylsilyl chloride (2.97 g, 19.7 mmol) in N,N-DMF (45 ml) were stirred at room temperature for 30 min. Triethylene glycol mono tosylate (5 g, 16.4 mmol) in DMF (40 ml) was added and stirring continued for 4 h. The solvent was removed under reduced pressure to approximately 5 ml and the residue diluted with H 2 O (100 ml), extracted with ether (3×75 ml), washed with brine (100 ml), dried (Na 2 SO 4 ), and concentrated. The resulting pale yellow oil was purified by flash chromatography (light petroleum-ethyl acetate; 85:15 to 70:30) to give 1-(t-butyldimethylsilyloxy)-3,6-dioxa-8-p-tosyloxy-octane as a clear oil (3.62 g, 52.6%). 1 H nmr (CDCl 3 ) δ0.08 (s, 6H), 0.88 (s, 9H), 2.44 (s, 3H), (3.54-3.73 (m, 10H), 4.16 (m, 2H), 7.33 and 7.79 (AB quartet, 2H each).
Lithium bromide (1.19 g) was added to 1-(t-butyldimethylsilyloxy)-3,6-dioxa-8-p-tosyloxy-octane (1.92 g) in dry acetone (15 ml) and the solution heated at reflux for 6 hours. The mixture was filtered through flash silica and subsequently washed with light petroleum-ethyl acetate (150 ml, 95:5). The solvent was removed under reduced pressure and the residue dissolved in ethyl acetate (100 ml), washed with brine (2×75 ml), dried (Na 2 SO 4 ), and concentrated to give 1-bromo-8-(t-butyldimethylsilyloxy)-3,6-dioxa-octane as a clear liquid (1.17 g, 78%). 1 H nmr (CDCl 3 ) δ0.06 (s, 6H), 0.89 (s, 9H), 3.41-3.86 (m, 12H); 13 C nmr (CDCl 3 ) δ−5.27, 18.36, 25.92, 30.25, 62.72, 70.59, 70.73, 71.22, 72.73; m/z 329, 327 (M+H) + .
Phytanol (19.5 g) was dissolved in acetic acid (250 ml) and cooled in an ice bath. Chromium trioxide (21.0 g) dissolved in a minimum amount of water was added to the above solution and stirred at room temperature for 18 hours. Ethanol (50 ml) was slowly added to the reaction mixture and stirred for a further 3 hours. Most of solvent was removed and water (250 ml) was added. This solution was extracted with ether (2×200 ml) and the combined ether extract was dried (MgSO 4 ), decolourized with activated charcoal and filtered through a thin flash silica bed. The solvent was removed and the crude product chromatographed on flash silica (1-4% methanol in dichloromethane) to give phytanoic acid as a pale yellow liquid. Yield 7.03 g, 34%.
Phytanoic acid (6.4 g) was dissolved in thionyl chloride (10 ml) and heated under reflux for 1.5 hours. Excess thionyl chloride was distilled off and the product dried under reduced pressure for one hour. This light yellow liquid was added dropwise into a solution of methylamine in tetrahydrofuran (2M solution in THF, 50 ml) and stirred for 18 hours. Most of the solvent removed under reduced pressure and the product partitioned between water (150 ml) and dichloromethane (100 ml). The organic layer was removed and washed with dilute hydrochloric acid and dried with magnesium sulfate. The solvent was removed and the crude product purified by column chromatography (flash silica, 4-10% methanol in dichloromethane). Yield 4.77 g, 70% 1 H-n.m.r. (CDCl 3 ) δ0.81-1.64 (m, 37H, phyt), 1.93 (m, 2H), 2.19 (m. 2H), 2.79 and 2.81 (s, 3H, NCH 3 ), 5.30 (s(b), 1H, NH); m/z (CI;CH 4 ) 326 (M + ), 270.
A mixture of N-methylphytanamide (4.0 g) and lithium aluminium hydride (pellets 95%, 2.0 g) in tetrahydrofuran (100 ml) was heated under reflux for two hours. The reaction mixture cooled, excess lithium aluminium hydride destroyed, and solid salts were filtered off. The crude product was dissolved in dichloromethane and washed with water, dried (MgSO 4 ) and the solvent removed. The crude product was chromatographed on flash silica (1% aqueous ammonia, 10-20% methanol in dichloromethane ) to give pure N-methylphytanamine as a colourless liquid. Yield 2.08 g, 54%. 1 H-n.m.r. (CDCl 3 ) δ0.82-1.5(m, 39H, phyt), 2.439 (s, 3H, NCH 3 ), 2.54 (m, 2H, CH 2 CH 2 NH).
N-Methylphytanamine (1.0 g) and succinic anhydride (1.0 g) were dissolved in pyridine (5 ml) and stirred at room temperature for 18 hours. The solvent was removed and the crude product dissolved in dichloromethane. This was washed with 2N hydrochloric acid, water and dried (MgSO 4 ). The crude product obtained after removal of solvent was chromatographed on flash silica (methanol 2-5% in dichloromethane) to give pure N-methylphytanamine hemisuccinamide as a colourless liquid. Yield 1.3 g, 100%. 1 H-n.m.r. (CDCl 3 ) δ0.82-1.55 (m, 39H, phyt), 2.69 (m, 4H, NCOCH 2 CH 2 CON), 2.95 and 3.01 (s, 3H, NCH 3 ), 3.25-3.5 (m, 2H, CH 2 CH 2 N).
N-Methylphytanamine hemisuccinamide (447 mg), N-methyl-N′-methyl-3,6,9-trioxa-1,11-diaminoundecane (1.2 g) and DCC (270 mg) was dissolved in dry dichloromethane (50 ml) and stirred for 96 hours at room temperature under nitrogen. The white precipitate formed was removed by filtration and the crude product obtained from the filtrate was chromatographed on flash silica (15% methanol in dichloromethane) to give N-methylphytanamine (N-methyl-N′-methyl-tetraethyleneglycylamine) succinamide as a colourless liquid. Yield 313 mg, 69%. 1 H-n.m.r. (CDCl 3 ) δ0.82-1.55 (m, 39H, Phyt), 2.45 (s(b), CH 2 NHCH 3 ), 2.64 (m, 4H, NCOCH 2 CH 2 CON), 2.76 (m, 2H, CH 2 NHCH 3 ), 2.91, 2.96, 3.01, 3.11 (s, 6H, CONCH 3 ), 3.36 (m, 2H, phytCH 2 N), 3.59 (m, 14H, CON(CH 3 )CH 2 CH 2 O—+OCH 2 CH 2 O—+O—CH 2 CH 2 NH CH 3 ).
N-Methylphytanamine (N-methyl-N′-methyl-tetraethyleneglycylamine) succinamide (461 mg) and succinic anhydride (200 mg) were dissolved in pyridine (10 ml) and stirred at room temperature for 48 hours. The solvent was removed and the crude product chromatographed on flash silica (1% acetic acid, 15% methanol in dichloromethane) to give pure (N-methylphytanamine (N-methyl-N′-methyl-3,6,9-trioxa-1,11-diaminoundecane) succinamide) hemisuccinamide as a colourless liquid. Yield 530 mg, 100%. 1 H-n.m.r. (CDCl 3 ) δ0.82-1.55 (m, 39H, Phyt), 2.68 (m, 8H, succinates), 2.91, 2.96, 3.01, 3.09, 3.11 (s, 9H, NCH 3 ), 3.36 (m, 2H, phytCH 2 N), 3.60 (m, 16H, N(CH 3 )CH 2 CH 2 O—+OCH 2 CH 2 O—); m/z (MALDI) 715, 714.
To a solution of ‘membrane spanning lipid C’ (see FIG. 4, n=4) (200 mg) in THF (7 ml), triethylamine (40 mg) was added. The mixture was cooled to 0° C. and methanesulfonyl chloride (45 mg) was introduced. This was stirred at room temperature for 24 h. Ether (20 ml) was added and the organic layer washed with a saturated solution of sodium hydrogen carbonate (2×20 ml), water (2×20 ml), dried (MgSO 4 ) and evaporated to give the product (220 mg, 98%). 1 H-n.m.r. (CDCl 3 ) δ0.82-1.78 (m, 130H, phytanyl and C-15 chain), 3.02 (s, 6H, methyl sulfonate), 3.39-3.68 (m, 14H, CH 2 —O), 3.97 (t, 4H, CH 2 —OPh), 4.19-4.39 (m, 4H, —CH 2 —OSO 2 Me), 6.93 (d, 4H) 7.45 (d, 4H, aromatic H). m/z (MALDI) 1507 (M + ).
A solution of MSL dimesylate (220 mg) in DMF (10 ml) containing sodium azide (30 mg) was heated at 110° C. for 48 h. Brine (50 ml) was added and the mixture extracted with ether (4×50 ml). The combined ether extract was washed with water (3×50 ml) dried and evaporated to give a waxy solid (195 mg, 95%). 1 H-n.m.r. (CDCl 3 ) δ0.82-1.79 (m, 130H, phytanyl and C-15 chain), 3.30-3.62 (m, 18H, CH 2 —O and —CH 2 —N 3 ), 3.97 (t, 4H, CH 2 —OPh), 6.93 (d, 4H) 7.45 (d, 4H, aromatic H). m/z (MALDI) 1376 (M + ).
The MSL diazide (400 mg, 0.28 mm) was dissolved in freshly distilled THF (12 ml) and the solution cooled to 0° C. Lithium aluminium hydride (0.4 ml, 1M solution in ether) was introduced and the reaction was stirred at room temperature for 24 h. Water (60 ml) was added and the solution extracted with chloroform (5×50 ml). The combined organic phase was washed with brine (50 ml) dried and evaporated to give the product (260 mg, 67%). 1 H-n.m.r. (CDCl 3 ) δ0.83-1.56 (m, 130H, phytanyl and C-15 chain), 2.74-2.83 (m, 4H, —CH 2 —NH2), 3.39-3.65 (m, 14H, CH 2 —O), 3.98 (t, 4H, CH 2 —OPh), 6.93 (4H,d) 7.45 (4H,d) (aromatic H). m/z (MALDI) 1348 (M + ).
Phytanyl bromide (12.34 g), potassium phthalimide (6.95 g) and DMF (50 ml) were heated at 120-130° C. for 4 hours. Most of the DMF was removed under reduced pressure and the crude product was dissolved in dichloromethane (100 ml), washed with water (2×50 ml), dried (MgSO 4 ). The light yellow crude product was chromatographed on flash silica (dichloromethane/hexane as eluant) to yield pure N-phytanyl phthalimide in 11.89 g (80.9%) 1 H-n.m.r. (CDCl 3 ) δ0.82-1.8 (m, 39H), 3.73 (t, 2H, CH 2 N), 7.73 (m, 2H, ArH), 7.88 (m, 2H, ArH); m/z 431 (M + ).
Phytanyl phthalimide (1.7 g) was dissolved in ethanol (100 ml) and hydrazine hydrate (2 ml) was added and heated under reflux for 2.5 hours. The reaction mixture was cooled and concentrated hydrochloric acid (1 ml) added. The white precipitate formed was filtered and the filtrate was neutralised with 20% sodium hydroxide. This aqueous solution was extracted, dried with magnesium sulphate and the solvent removed under reduced pressure. This product was used without further purification. 1 H-n.m.r. (CDCl 3 ) δ0.82-1.8 (m, 39H), 3.65 (t, 2H, NCH 2 ); m/z (CI CH 4 ) 297 (M+H), 283, 281, 225, 211, 197, 183,169, 155, 141, 127, 113, 99, 85, 71.
Phytylamine (2.32 g), succinic anhydride (1.16 g) and pyridine (10 ml) was stirred at room temperature for 48 hours. Most of the pyridine was removed under reduced pressure and the crude product dissolved in dichloromethane and washed with 2M HCl (2×100 ml). The organic was layer separated, dried (MgSO 4 ) and concentrated in vacuo to dryness. The crude product was chromotographed (ethyl acetate as eluant) to give phytanamine hemisuccinamide 1.23 g (91%) as a thick liquid which solidified on standing 1 H-n.m.r. (CDCl 3 ) δ0.8-1.8 (m, 39H), 2.5 (m, 2H, CH 2 COO—), 2.6 (m, 2H, CH 2 COOH), 3.2 (m, 2H, CH 2 N—), 5.79 (b, 1H, NH), m/z (CI, CH 4 ), 412 (M + )
3,6,9-Trioxa-1,11-diaminoundecane (1.03 g), BOC-ON (1.38 g, 5.62 mmol), triethylamine (0.81 g) were dissolved in 1:1 mixture of water and dioxane (40 ml). The reaction mixture was stirred at room temperature for 24 hours and the bulk of the solvent removed under reduced pressure. The crude product was dissolved in water and extracted with dichloromethane (4×100 ml). The combined organic extract was dried (MgSO 4 ) and the solvent removed under reduced pressure to give the crude product as a thick liquid. This was chromotographed on flash silica (20% methanol in dichloromethane as eluant) to give N-(t-butyloxycarbonyl)-3,6,9-trioxa-1,11-diaminoundecane 0.16 g (26%) as a colourless thick liquid. 1 H-n.m.r. (CDCl 3 ) δ1.44 (s, 9H, t Bu), 2.85 (b, 2H, CH 2 NH 2 ), 3.31 (m, 2H, CH 2 NHCOOtBu), 3.30-3.70 (m, 8H, OCH 2 ), 5.4 (b, 1H, CH 2 NHCOOtBu); m/z 293 (M + ), 265, 237, 193.
N-(t-butyloxycarbonyl)-3,6,9-trioxa-1,11-diaminoundecane (626 mg), mono-protected diamine (390 mg), morpho-CDI, (733 mg) and DMAP (192 mg) was dissolved in dichloromethane (10 ml) and stirred under nitrogen for 24 hours. The white precipitate formed was filtered and the solvent removed in vacuo. The crude product was chromatographed on flash silica (5-10% methanol in dichloromethane as eluant) to give the product as a thick, light yellow liquid. Yield 403 mg, 71%. 1 H-n.m.r. (CDCl 3 ) δ0.82-1.55 (m, 48H, phyt+ t Bu), 2.52 (m, 4H, NCOCH 2 CH 2 CON), 3.22-3.64 (m, 8H, NCH 2 CH 2 O+OCH 2 CH 2 O), 5.15 (m, 1H, NH), 6.0 (m, 1H, NH), 6.4 (m, 1H, NH); m/z 673 (M+H) + , 599, 573, 437, 380, 275, 219.
Phytanamine (N-(t-butyloxycarbonyl)-36,9-trioxa-1,11-diaminoundecane)succinamide (1.5 g, 2.23 mmol) was dissolved in trifluoroacetic acid (TFA) (10 ml) and allowed to stand at room temperature for 2 hours. TFA was removed under reduced pressure and the residue was chromatographed as the TFA salt of the amine (flash silica, 2-5% methanol in dichloromethane as eluant). This product was dissolved in dichloromethane and stirred with potassium carbonate to give the free amine as a colourless liquid. 1.33 g, 100%. 1 H-n.m.r. (CD 3 OD) δ0.62-1.4 (m, 39H, Phyt), 2.23 (s, 4H, NCOCH 2 CH 2 CON), 2.6 (m(b), 2H, —CH 2 NH 2 ), 2.9-3.4 (m, 16H, CH 2 NH+NHCH 2 CH 2 O—+OCH 2 CH 2 O); m/z (CI, CH 4 ) 572 (M+), 380, 275.
Phytanamine (3,6,9-trioxa-1,11-diaminoundecane)succinamide (1.3 g) was dissolved in pyridine (25 ml) and succinic anhydride (340 mg, 3.4 mmol) was added. The reaction mixture stirred at room temperature for 24 hours and solvent removed. The crude product was chromatographed on flash silica (3-10% methanol in dichloromethane as eluant) to yield pure 1.22 g (80%) (phytanamine (3,6,9-trioxa-1,11-diaminoundecane)succinamide) hemisuccinamide. 1 H-n.m.r. (CDCl 3 ) δ0.85-1.6 (m, 49H, Phyt), 2.5-2.7(m, 8H, NCOCH 2 CH 2 CON), 3.22 (m, 2H, CH 2 NH), 3.43(m, 4H, —OCH 2 CH 2 NH—), 3.56 (OCH 2 CH 2 NH—), 3.65 (s, 8H, OCH 2 CH 2 O—), 6.29 (m, 1H, NH), 6.90 (m, 1H, NH), 7.11 (m, 1H, NH); m/z (CI, CH 4 ) δ55 (M−H 2 O) + , 380, 298.
Sodium hydride (276 mg) was added portionwise to a stirred solution of trans 1,2-dithiane-4,5-diol (1 g) in dry THF (50 ml) under N 2 over 30 min. After stirring at room temperature for 30 min., methyl iodide (6 ml) was added in 3 equal portions approximately 30 min. apart. After 4 h, the reaction solution was concentrated under reduced pressure to approximately 5 ml and saturated aqueous NH 4 Cl (10 ml) was added, followed by water (75 ml). The aqueous layer was extracted with dichloromethane (3×60 ml) and the organic layers combined, washed with brine (50 ml) and dried (Na 2 SO 4 ). The solvent was removed under reduced pressure to give 993 mg of a mixture of mono and di substituted products (91% yield, 75:25 ratio, respectively) as a yellow/cloudy oil. The products were separated by flash column chromatography using Dichloromethane-MeOH (100:0 to 99:1) as eluant to give 4RS,5RS-4-hydroxy-5-methoxy-1,2-dithiacyclohexane from the most polar fractions (600 mg, 60%). 1 H-n.m.r. (CDCl 3 ) δ2.73 (br s, 1H), 2.83 (dd, 1H), 2.99 (br dd, 1H), 3.05-3.19 (m, 2H), 3.22-3.28 (m, 1H), 3.44 (s, 3H), 3.66-3.73 (m, 1H). 13 C-n.m.r. (CDCl 3 ) δ36.4, 39.9, 56.9, 73.0, 84.1.
A mixture of sodium sulfide nonahydrate (18 g), sulfur (12 g) and sodium hydroxide (10.4 g) in H 2 O (120 ml) was heated on a steam bath for 20 min. after which time a solution of 2,2-bis-(bromomethyl)-1,3-propanediol (5.0 g) in ethanol (50 ml) was added. The resulting mixture was refluxed for 3 h, cooled to room temperature and diluted with H 2 O (500 ml). The solution was extracted (continuous liquid-liquid extraction) with ether and the organic phase dried (Na 2 SO 4 ). The solvent was removed under reduced pressure to afford a pale yellow crystalline solid which was recrystallised from toluene to give 4,4′-bishydroxymethyl-1,2-dithiacyclopentane as pale yellow plates (1.26 g, 40%); m.p. 129° C. Found: C, 36.4; H, 6.1%. C 5 H 10 O 2 S 2 requires C, 36.09; H, 6.02%. 1 H-n.m.r. (CDCl 3 ) δ2.85 (br s, 4H), 3.60 (d, 4H), 4.40 (t, 2H).
A solution of 4,4′-bishydroxymethyl-1,2-dithiacyclopentane (3 g) in THF (40 ml) was added to a suspension of sodium hydride (0.44 g) in THF (15 ml) under nitrogen. The mixture was stirred for 1 h at room temperature and methyl iodide (7.62 g) was added portionwise over 3 h and the resulting mixture was left to stir for 16 h. Water (20 ml) was added and the aqueous layer was extracted with ethyl acetate (5×50 ml). The combined organic layers were washed with brine (3×50 ml) and dried (Na 2 SO 4 ). The solvent was removed under reduced pressure and the product purified by flash chromatography (ethyl acetate-light petroleum, 1:1 as eluant). 4-Hydroxymethyl-4-methoxymethyl-1,2-dithiacyclopentane was obtained as a crystalline solid (2.4 g, 74%); m.p. 49-50° C. Found: C, 40.1; H, 6.8%. C 6 H 12 O 2 S 2 requires C, 40.0; H, 6.67%. 1 H-n.m.r. (CDCl 3 ) δ2.88 (s, 1H), 2.89 (AB quartet, 4H), 3.33 (s, 3H), 3.41 (s, 2H), 3.61 (s, 2H). 13 C-n.m.r. (CDCl 3 ) δ44.5, 56.4, 59.4, 66.9, 76.8.
A solution of 4-Hydroxymethyl-4-methoxymethyl-1,2-dithiacyclopentane (0.1 g) in THF (20 ml) was added to a suspension of sodium hydride (0.03 g) in THF (20 ml) and the mixture was stirred at room temperature for 30 min. Ethylene sulfate (0.14 g) was added and the resulting mixture stirred at room temperature for 48 h. Hydrochloric acid (3M, 5 ml) was added, and the aqueous layer extracted with ethyl acetate (5×20 ml). The organic layers were combined and washed with water (50 ml) and dried (Na 2 SO 4 ). The solvent was removed under reduced pressure and the resulting oil purified by flash chromatography (ethyl acetate-light petroleum, 1:1 as eluant) to give 4-(2-hydroxyethoxy)methyl-4-methoxymethyl-1,2-dithiacyclopentane (66.8 mg, 54%). 1 H-n.m.r. (CDCl 3 ) δ2.93 (AB quartet, 4H), 3.34 (s, 3H), 3.36 (s, 2H), 3.46 (s, 2H), 3.56 (m, 2H). 3.70 (m, 2H); 13 C-n.m.r. (CDCl 3 ) δ44.7, 56.2, 59.3, 61.6, 72.2, 72.3, 74.2; m/z 224 (M + )
A 60% dispersion of sodium hydride in mineral oil (156 mg) was washed with light petroleum (2×4 ml) and dissolved in THF (7.5 ml). 4RS,5RS-4-Hydroxy-5-methoxy-1,2-dithiacyclohexane in THF (7.5 ml) was slowly added and the mixture stirred for 15 min. A solution of 1-bromo-8-(t-butyldimethylsilyloxy)-3,6-dioxa-octane in THF (10 ml) was added followed by tetrabutyl ammonium iodide (0.56 g) and stirring continued for 6 days. The solvent was removed under reduced pressure to approximately 5 ml and saturated aqueous NH 4 Cl (5 ml) was added followed by H 2 O (100 ml). The aqueous phase was extracted with dichloromethane (3×75 ml) and the combined organic phase was washed with brine (100 ml), dried (Na 2 SO 4 ), and concentrated. The resulting rust coloured semi-solid was purified by flash chromatography (light petroleum-ethyl acetate; 60:40) to give 4RS,5,RS-4-(8-t-butyldimethylsilyloxy-3,6-dioxa-1-octanyloxy)-5-methoxy-1,2-dithiacyclohexane as a yellow liquid (190 mg, 15.3%). 1H nmr (CDCl 3 ) δ0.06 (s, 6H), 0.88 (s, 91), 2.73-2.95 (m, 2H), 3.47 (s, 3H), 3.11-3.80 (m, 16H); 13 C-nmr (CDCl 3 ) δ−5.30, 18.32, 25.89, 37.91, 38.39, 58.36, 62.67, 70.41, 70.61, 70.70, 70.88, 72.64, 91.26, 82.19.
Tetrabutylammonium fluoride (1.1 ml, 1M solution in THF) was added to 4RS,5BS-4-(8-t-butyldimethylsilyloxy-3,6-dioxa-1-octanyloxy)-5-methoxy-1,2-dithiacyclohexane (182 mg) in THF (2.5 ml) at 0° C. and stirred for 5 min, after which time the solution was slowly warmed to room temperature and stirring continued for 24 h. The solvent was removed to approximately 5 ml and the resulting residue diluted with H 2 O (50 ml), extracted with dichloromethane (3×40 ml), washed with brine (75 ml), dried (Na 2 SO 4 ), and concentrated. The resulting pale yellow oil was purified by flash chromatography (ethyl acetate) to give 4RS,5RS-4-(3,6-dioxa-8-hydroxy-1-octanyloxy)-5-methoxy-1,2-dithiacyclohexane as a rust coloured oil (117 mg, 88.7%). 1 H nmr (CDCl 3 ) δ2.76-2.94 (m, 3H), 3.13-3.41 (m, 6m), 3.46 (s, 3H), 3.57-3.80 (m, 12H); 13 C nmr (CDCl 3 ) δ37.83, 38.28, 58.22, 61.68, 70.20, 70.30, 70.55, 70.83, 72.52, 81.16, 82.18
4-(3,6-Dioxa-8-hydroxy-1-octanyloxy)methyl)-4-methoxymethyl-1,2-dithiacyclopentane was prepared following the procedure for the synthesis of 4-(3,6-dioxa-8-hydroxy-1-octanyloxy)-5-methoxy-1,2-dithiacyclohexane, though replacing 4RS,5RS-4-hydroxy-5-methoxy-1,2-dithiacyclohexane with (4-hydroxymethyl-4-methoxymethyl-1,2-dithiacyclopentane. 1 H nmr (CDCl 3 ) d 2.95 (s, 4H), 3.36 (s, 3H), 3.38 (s, 2H), 3.46 (s, 2H), 3.5-3.8 (m, 12H); m/z 313 (M+H) + .
4RS,5RS-4-(3,6-Dioxa-8-hydroxy-1-octanyloxy)-5-methoxy-1,2-dithiacyclohexane (66 mg) in Dichloromethane (10 ml) was stirred with DMAP (54 mg), DMAP-HCl (71 mg), morpho-CDI (187 mg) and ((3,6,9-trioxa-undecanyl) phytanyl succinate) hemisuccinate (224 mg) at 0° C. and allowed to slowly warm to room temperature. A white precipitate formed during the initial 24 h and persisted throughout the reaction. After 48 h the mixture was filtered through Celite®. The solvent was removed under reduced pressure and the waxy white residue dissolved in ethyl acetate (75 ml), washed with hydrochloric acid (50 ml, 3M), brine (50 ml), dried (Na 2 SO 4 ), and concentrated. The resulting yellow viscous oil was purified by flash chromatography (ethyl acetate) to give mono methoxy dithiane-TREG-Succ-TEGSucc-Phyt as a clear viscous oil (171 mg, 81%); 1 H nmr (CDCl 3 ) δ0.83 (s, 3H), 0.849 (s,3H), 0.854 (s, 3H), 0.877 (s, 3H), 0.899 (s, 3H), 1.04-1.69 (br m, 24H), 2.61-2.66 (m, 8H), 2.86 (ddd, 2H), 3.18 (br ddd, 2H), 3.27 (m, 1H), 3.39 (m, 1H), 3.47 (s, 3H), 3.61-3.79 (brm, 24H), 4.12 (m, 2H), 4.25 (m, 6H); 13 C nmr (CDCl 3 ) δ19.46, 19.52, 19.68, 19.74, 22.61, 22.70, 24.30, 24.47, 24.78, 27.96, 28.99, 29.06, 29.13, 29.88, 32.77, 35.46, 35.55, 37.28, 37.39, 39.37, 58.35, 63.40, 63.83, 69.08, 70.42, 70.59, 70.96, 172.21; m/z (MALDI) 978 (M+Na 30 )
(4-Methoxymethyl-4-triethyleneglycyloxymethyl)-1,2-dithiacyclopentyl succinate tetraethyleneglycyl succinate phytanyl was prepared following the procedure for the synthesis of monomethoxy dithiane-(triethyleneglycyl succinate tetraethyleneglycyl succinate phytanyl), though replacing 4RS,5RS-4-(3,6-dioxa-8-hydroxy-1-octanyloxy)-5-methoxy-1,2-dithiacyclohexane with (4-(3,6-dioxa-8-hydroxy-1-octanyloxy)methyl)-4-methoxymethyl-1,2-dithiacyclopentane. 1 H nmr (CDCl 3 ) δ0.84-0.92 (m, 15H), 1.1-1.7 (m, 24H), 2.63 (m, 8H), 2.93 (s, 4H), 3.36 (s, 3H), 3.40 (s, 2H), 3.45 (s, 2H), 3.60-3.75 (m, 22H), 4.1 (m, 2H), 4.25 (m, 6H); m/z (MALDI) 1008 (M + K + ).
4-Hydroxymethyl-4methoxymethyl-1,2-dithiacyclopentane (0.05 g) was added to a solution of ((3,6,9,12,15-pentaoxa-heptadecanyl) phytanyl succinate) hemisuccinate (0.21 g, 0.28 mmole), morpho-CDI (0.14 g), DMAP (0.011 g) and DMAP:HCl (0.015 g) in dichloromethane at room temperature under nitrogen and stirred for 2 days. The reaction mixture was diluted with water (20 ml) and then extracted with ethyl acetate (4×20 ml) washed with 1M HCl (10 ml), water and brine. The combined ethyl acetate extracts were dried (Na 2 SO 4 ). filtered and the solvent removed in vacuo. The organic residue was chromotographed on flash silica with ethyl acetate-light petroleum (1:1) to give 0.15 g (56%) of the title compound as a pale yellow oil. Anal. Calc'd. for C 46 H 84 O 13 S 2 : C, 59.64; H, 9.2%. Found: C, 59.42; H, 9.57%; 1 H NMR (CDCl 3 ), δ0.83-0.90 (m, —CH 3 , 15H), 1.23-1.27 (m, —CH 2 , —CH, 24H), 2.65 (m, CH 2 COO, 8H), 3.34(s, —OCH 3 , 3H), 3.35 (s, —OCH 2 CH 3 , 2H), 2.99 (AA′BB′, 2H), 2.98 (2H), 3.69 (td, 4H), 3.65 (s, —CH 2 O—, 18H), 4.24 (td, 4H. m/z (MALDI) 925.
4-Hydroxymethyl-4methoxymethyl-1,2-dithiacyclopentane (0.05 g) was added to a solution of ((3,6,9,12,15-pentaoxa-heptadecanyl) (diphytanyl)glyceryl succinate) hemisuccinate (0.31 g), DCC (0.07 g), DMAP (0.004 g) in dichloromethane at room temperature under nitrogen and stirred for 3 days. The reaction mixture was filtered, and the solvent removed under vacuum. The organic residue was chromatographed on flash silica (ethyl acetate-light petroleum, 1:1, then 100% ethyl acetate) to give 0.22 g (63%) of the title compound as a yellow oil. Anal. Calc'd. For C 69 H 130 O 16 S 2 : C,64.75; H, 10.24%. Found: C, 64.54; H, 10.42%; 1 H NMR (CDCl 3 ), δ0.80-0.84 (m, —CH 3 , 30H), 1.05-1.6 (m, —CH 2 ,—CH, 48H), 2.63 (m, CO—CH 2 —CH 2 —CO, 8H), 2.94 (s, S—CH 2 , 4H), 3.31 (s, —OCH 3 ), 3.33 (s, —CH 2 OCH 3 , 2H), 3.45 (m, glyc. CH 2 , 4H), 3.62 (m,—OCH 2 CH 2 O—, 20H), 3.69 (m, —CH 2 O, 4H), 4.13 (m, CH 2 O—, 4H). 4.14 (s, —CH 2 OC═O, 2H), 4.24 (m, COOCH 2 —, 4H); m/z (ES) 1279.
4,4-Bishydroxymethyl-1,2-dithiacyclopentane (0.05 g) was added to a solution of ((3,6,9,12,15-pentaoxa-heptadecanyl) phytanyl succinate) hemisuccinate (0.228 g), morpho-CDI (0.15 g), DMAP (0.011 g) and DMAP:HCl (0.016 g) in dichloromethane at room temperature under nitrogen and stirred for 2 days. The reaction mixture was diluted with water (20 ml) and then extracted with ethyl acetate (20 ml×4), washed with 1M HCl (10 ml), water and brine. The combined ethyl acetate extracts were dried over sodium sulfate. filtered and the solvent removed under vacuum. The organic residue was chromotographed on flash silica with ethyl acetate to give the title compound 0.12 g (42%) as a pale yellow oil. Anal. Calc'd. For C 45 H 82 O 14 S 2 : C, 59.31; H, 9.07%. Found: C, 59.09; H, 9.08%; 1 H NMR (CDCl 3 ), δ0.83-0.90 (m, —CH 3 , 15H), 1.23-1.27 (m, —CH 2 ,—CH, 24H), 2.61-2.68 (m, CO—CH 2 —CH 2 —CO, 8H), 2.93 (s, S—CH 2 , 4H), 3.53 (s, —CH 2 OH, 2H), 3.65 (s, —OCH 2 CH 2 O—, 16H), 3.68-3.71 (m, CH 2 —O, 4H), 4,12 (m, —CH 2 O0, 4H), 4.20(s, —CH 2 OC═O, 2H), 4.24 (td, COO—CH 2 —CH 2 , 4H); m/z 910 (M + ).
Mercaptoacetic acid disulfide (0.01 g) was added to a solution of (2-(1,2-dithiacyclopentyl)-2-hydroxy)ethyl-succinate-hexaethyleneglycyl-succinate-phytanyl (0.1 g) morpho-CDI (0.056 g), DMAP (0.0045 g), DMAP.HCl (0.0058 g) in dichloromethane at room temperature under nitrogen and stirred for 2 days. The reaction mixture was diluted with water (20 ml) and then extracted with ethyl acetate (5×20 ml), washed with 1M HCl (10 ml) water and brine. The combined ethyl acetate extracts were dried over sodium sulfate, filtered and the solvent removed under vacuum. The crude oil was chromatographed on flash silica (ethyl acetate) to give 10 mg of pure compound. m/z (MALDI) 1992 (M+Na + ).
Tribromoneopentyl alcohol (4.72 g) was added to a solution of potassium thiocyanate (8.5 g) in DMF (15 ml) at 100° C. under N 2 . The solution was heated at 140° C. for 30 min. then stirred for 16 hours at room temperature. The resulting suspension was diluted with H 2 O (150 ml) and extracted with ether (3×100 ml). The combined ether layers were washed with brine (2×200 ml), dried (Na 2 SO 4 ) and the solvent removed under reduced pressure. Recrystallisation from CHCl 3 gave tris(thiocyanato)neopentyl alcohol as colourless needles (3.05 g, 81%); m.p. 80-81° C. 1 H-n.m.r. (d 6 -DMSO) δ3.34 (s, 6H), 3.56 (d, 2H), 5.57 (t, 1H); 13 C-n.m.r. (d 6 -DMSO) δ37.5, 45.0, 63.3, 113.6.
A solution of tris(thiocyanato)neopentyl alcohol (0.26 g) and succinic anhydride (0.15 g) in dry pyridine (2 ml) was stirred at room temperature under nitrogen for 3 days. The reaction mixture was poured into hydrochloric acid (1M, 10 ml ) and extracted with Dichloromethane (3×40 ml). The combined organic layers were washed with H 2 O (4 ml) and the aqueous washings re-extracted with Dichloromethane (2.5 ml). The combined organic extracts were dried (Na 2 SO 4 ), filtered and the solvent removed under reduced pressure. The oily residue was stirred with chloroform (10 ml) and the resultant crystalline precipitate isolated by filtration and dried to give 2,2,2-tris-(thiocyanatomethyl)ethyl hemisuccinate as a colourless solid (0.30 g, 84%). 1 H-n.m.r. (d 6 -DMSO) δ2.5-2.7 (m, 4H), 3.53 (s, 6H), 4.24 (s, 2H). 13 C-n.m.r. (d 6 -DMSO) δ28.8, 29.0, 37.2, 44.0, 64.4, 113.1, 171.4, 173.5.
2,2,2-tris-(Thiocyanatomethyl)ethyl hemisuccinate (0.675 g) and 17-hydroxy-3,6,9,12,15-pentaoxa-heptadecan-1-yl phytanyl succinate (125 g) were suspended in dry dichloromethane (70 ml) at room temperature under nitrogen . A mixture of morpho-CDI (1.593 g), DMAP (0.689 g) and DMAP.HCl (0.6 g) was added in solid form to the above stirred suspension, to form a colourless solution. Stirring was continued under nitrogen for 4 days, during which time a crystalline solid precipitated. The reaction mixture was washed with water (2×70 ml), 1M HCl (70 ml) and brine (70 ml), dried (Na 2 SO 4 ), filtered and the solvent removed at 35° C. to give a pale yellow oil (1.90 g, 100%). Chromatography on silica gel with ethyl acetate as eluant yielded the pure title compound (1.79 g, 90%) as an extremely viscous colourless oil. 1 H-n.m.r. (CDCl 3 ) δ0.75-0.91 (15H, m, 5×phytanyl Me), 0.91-1.70 (24H, m, phytanyl), 2.58-2.76 (8H, 4×succinate CH 2 ), 3.34 (6H, s, 3×CH 2 S), 3.59-3.72 (20H, m, 10×HEG CH 2 ), 4.10 (2H, m, phytanyl OCH 2 ), 4.24 (4H, m, 2×HEG CH 2 OCO), and 4.32 (2H, s, OCH 2 ); 13 C-n.m.r. (CDCl 3 ) δ19.42-19.66 (m, 3×Me), 22.60 (Me), 22.69 (Me), 24.28 (CH 2 ), 24.44(CH 2 ), 24.76 (CH 2 ), 27.94 (CH), 29.02 (m, CH 2 OCO), 29.83 (CH), 32.74 (CH), 35.41 and 35.49 (phytanyl 2-CH 2 ), 36.70 (CH 2 ), 37.24 (CH 2 ), 37.34 (CH 2 ), 39.73 (CH 2 ), 45.62 (quaterary), 63.25 (CH 2 O), 63.38 (CH 2 O), 63.79 (CH 2 O), 64.17 (CH 2 O), 68.90 (CH 2 ), 69.03 (CH 2 ), 70.53 (CH 2 O), 111.17 (SCN), 171.52 (CO), 172.31 (CO), and 172.46(CO); m/z (MALDI) 1028, 1029. (M+Na + requires 1027).
2,2,2-tris-(Thiocyanatomethyl)ethyl-succinate-hexaethyleneglycyl-succinate-phytanyl (0.592 g) was dissolved in dry tetrahydrofuran (4.5 ml) and chilled to 0° C. under nitrogen. Tetrabutylammonium fluoride (0.59 ml 1M solution in THF) was added with stirring over 15 min at 0° C. and the red solution stirred for 5 min at 0° C., then at room temperature for 48 h. The mixture was diluted with ethyl acetate (30 ml), washed with water (2×15 ml), dried (Na 2 SO 4 ), filtered and the solvent removed at 40° C. to give a red oil (0.55 g, 98%). Chromatography on silica gel, eluting with light petroleum/ethyl acetate mixtures, yielded the title compound (0.47 g, 84%) as a pale yellow oil. 1 H-n.m.r. (CDCl 3 ) δ0.75-0.95 (m, 15H, 5×phytanyl Me), 0.95-1.75 (m, 24H, phytanyl), 2.69-2.72 (m, 8H, 2×succinate CH 2 ), 3.09 (s, 4H, CH 2 SSCH 2 ), 3.33 (s, 2H, CH 2 SCN), 3.58-3.74 (m, 20H, 10×HEG CH 2 ), 4.12 (m, 2H, phytanyl OCH 2 ), 4.24 (m, 4H, 2×HEG CH 2 OCO) and 4.27 (s, 2H, OCH 2 ); 13 C-n.m.r. (CDCl 3 ) δ19.43-19.72, (m, 3×Me), 22.59 (Me), 22.69 (Me), 24.27 (CH 2 ), 24.44 (CH 2 ), 24.76 (CH 2 ), 27.93 (CH), 28.88-29.09 (m, CH 2 OCO), 29.83 (CH), 32.74 (CH), 35.41 and 35.49 (phytanyl 2-CH 2 ), 37.24 (CH 2 ), 37.35 (CH 2 ), 39.33 (CH 2 ), 39.65 (CH 2 ), 45.88 (CH 2 S), 56.46 (quaternary), 63.37 (CH 2 O), 63.79 (CH 2 O), 64.03 (CH 2 O), 65.85 (CH 2 O), 68.97 (CH 2 O), 69.03 (CH 2 O), 70.55 (CH 2 O), 112.07 (SCN), 171.62 (CO), 172.20 (CO) and 172.29 (CO): m/z (MALDI) 975; (M +Na + ) requires 975; m/z (DCI in NH3) 970; (M+NH 4 + ).
2-(1,2-Dithiacyclopentyl)-2-thiocyanatomethyl)ethyl-succinate-hexaethyleneglycyl-succinate-phytanyl (0.36 g) was dissolved in dry tetrahydrofuran (1.6 ml) under nitrogen at room temperature. Tetrabutylammonium fluoride (0.57 ml 1M solution in THF) was added slowly with stirring and the mixture stirred for 17 h. A further 0.5 eq. of TBAF was added (total 2.0 eq) and stirring continued for an additional 3 h. The mixture was diluted with ethyl acetate (40 ml), washed with water (2×20 ml), dried (Na 2 SO 4 ), filtered and the solvent evaporated at 40° C. to give a red-brown oil (0.36 g). Chromatography on silica gel with ethyl acetate as eluant afforded the title compound as a pale yellow oil (0.24 g, 69%). 1 H-n.m.r. (CDCl 3 ) δ0.75-0.92 (m, 30H, 5×phytanyl Me), 0.92-1.73 (m, 48H, phytanyl), 2.56-2.67 (m, 16H, 8×succinate CH 2 ), 2.93-3.18 (m, 12H, 3×CH 2 SSCH 2 ), 3.55-3.70 (m, 40H, 20×HEG CH 2 ), 4.08 (m, 4H, phytanyl OCH 2 ) and 4.14-4.26 (m, 12H, 4×HEG CH 2 OCO and 2×OCH 2 ); 13 C-n.m.r. (CDCl 3 ) δ19.34-19.64, (m, Me), 22.51 (Me), 22.60 (Me), 24.16 (CH 2 ), 24.33 (CH 2 ), 24.66 (CH 2 ),27.83 (CH), 28.77-28.98 (m, CH 2 OCO), 29.72 (CH), 32.63 (CH), 35.31 and 35.39 (phytanyl 2-CH 2 ), 37.13 (CH 2 ), 37.24 (CH 2 ), 39.23 (CH 2 ), 45.74 (CH 2 S), 46.19 (CH 2 S), 55.30 (quaternary), 63.24 (CH 2 O), 63.67 (CH 2 O), 63.85 (CH 2 O), 66.35 (CH 2 O), 68.92 (CH 2 O), 70.43 (CH 2 O), 171.55 (CO). 172.02 (CO) and 172.18 (CO); m/z (MALDI) 1876; 927;(M +Na + ) requires 1875; M / 2 requires 926.
Below are representative impedance results for the derivatives synthesised above:
EXAMPLE 1
The structure of “linker lipid A” is shown in FIG. 2; the structure of “linker gramicidin B” is shown in FIG. 3; the structure of “membrane spanning lipid D” is shown in FIG. 4; the structure of “membrane spanning lipid C” where n=4 is shown in FIG. 4; the structure of “biotinylated gramicidin E” where n=5, is shown in FIG. 5 .
A glass slide or plastic support was evaporatively coated with a 200 Å chromium adhesion layer, followed by a 1000 Å layer of gold. The gold coated substrate was placed in a 50 ml ethanolic solution containing the components as listed in Table 1, in the concentrations shown.
TABLE 1
COMPONENT
MOLARITY
Linker lipid A
370
μM
Mercaptoacetic acid Disulfide
185
μM
Membrane spanning lipid C
27.75
nM
(where n = 4)
Membrane spanning lipid D
5.55
μM
Linker gramicidin B
55.5
nM
The gold coated substrate is preferably placed into this solution within five minutes of preparation. The gold coated substrate is left in this solution for 60 minutes, and then rinsed copiously with ethanol, and then immersed in ethanol for 2-3 hours. The gold slide is then rinsed with ethanol and is assembled in an electrode holder such that an electrode is defined. that for the current examples has an area of approximately 11 mm 2 . Then, 10 μl of an ethanolic solution of 1,2-di(3RS,7R,11R-phytanyl)-glycero-3-phosphocholine and 1,2-di(3RS,7R,11R-phytanyl)glycerol in a 7:3 ratio, 3 mM total lipid concentration, containing biotinylated gramicidin E where n=5, in a concentration such that the ratio of total lipid to gramicidin derivative is 67,000:1 is added to the surface of the gold electrode and then rinsed with three washes of 150 μl PBS, leaving 100 μl PBS above the electrode surface. A counter electrode, typically silver, is immersed in the PBS solution; and the counter electrode and the sensing electrode are connected to an impedance bridge. A DC offset of −300 mV is applied to the sensing electrode during AC measurement. Then 5 μl of 0.1 mg/ml solution of streptavidin is added to the electrode well, left for three to five minutes, and rinsed with PBS (3×150 μl). Biotinylated anti-ferritin Fab's (5 μl of 0.05 mg/ml solution in PBS), is then added and after three to five minutes the electrode well rinsed with PBS. The biotinylated Fab's were biotinylated via the free thiol group of freshly cleaved (Fab) 2 dimers. The response to 100 μl of a 200 pM solution of ferritin is then monitored via impedance spectroscopy.
The new feet were examined individually by replacing linker lipid A and mercaptoacetic acid disulfide in the first layer solutions with the new sulfur containing compound. Identical quantities and methods of addition of the second layer solution, streptavidin and ferritin allowed for direct comparison with the conventional bilayer biosensor.
Selected examples of the advantages of the new feet are illustrated below.
EXAMPLE 2
A first layer solution was prepared using the same concentrations of components as tabulated in Table 1 except replacing linker lipid A with the compound shown directly below in the same concentration, and removing mercaptoacetic acid disulfide from the solution. The assembly was then completed as described in example 1.
The ferritin gating experiment employing this bigfoot derivative shows similar gating response (see Table 2) to that obtained for the system described in example 1.
TABLE 2
Preparation
Gating response to Ferritin
Example 1
48 ± 4%
Example 2
49 ± 4%
EXAMPLE 3
A first layer solution was prepared using the same concentrations of components as tabulated in Table 1 except replacing linker lipid A with the compound shown directly below in the same concentration, and removing mercaptoacetic acid disulfide from the solution. The assembly was then completed as described in example 1.
The bilayer membrane obtained using this bigfoot derivative yields a more conductive membrane compared to the system prepared in Example 1 (see Table 3). It is noteworthy that the absence of mercaptoacetic acid from the first layer solution described in Example 1 generates bilayer membranes with lower conductivity compared to that obtained for Example 1 and Example 3.
TABLE 3
Preparation
Freq @ phase min.
Example 1
44
Example 2
193
EXAMPLE 4
A first layer solution was prepared using the same concentrations of components as tabulated in Table 1 except replacing linker lipid A with the compound shown directly below in the same concentration, and removing mercaptoacetic acid disulfide from the solution. The assembly was then completed as described in example 1.
The ferritin gating experiment employing this bigfoot derivative shows a reduced gating response time compared to the assembly described in Example 1 (see Table 4).
TABLE 4
Tau for response to
Preparation
Ferritin
Example 1
190
Example 4
56
EXAMPLE 5
A first layer solution was prepared using the same concentrations of components as tabulated in Table 1 except replacing linker lipid A with the compound shown directly below in the same concentration. The assembly was then completed as described in Example 1.
The ferritin gating experiment employing this bigfoot derivative shows a significantly reduced gating response time compared to the assembly described in Example 1 (see Table 5).
TABLE 5
Tau for response to
Preparation
Ferritin
Example 1
190
Example 5
38
EXAMPLE 6
A gold coated substrate, prepared as described in Example 1, was immersed for 1 hour in a 1 mM ethanolic solution of the bigfoot derivative shown below.
The gold coated substrate should preferably be placed into this solution within five minutes of preparation. The gold coated substrate was left in this solution for 60 minutes, and then rinsed copiously with ethanol, and then immersed in ethanol for 2-3 hours. The gold slide was then rinsed with ethanol, dried in the air, and then mounted in a ultra high vacuum chamber of an Escalab 200 IXL X-ray Photoelectron Spectrometer (XPS). The gold coated substrate was then exposed to monochromatic X-ray irradiation of 1464 eV at ˜45° to the surface. The energy spectrum was recorded normal to the surface and the carbon (C 1s), oxygen (O 1s), sulfur (S p 1/2 and S p 3/2 ) and gold (Au 4f 7/2 ) spectra were recorded.
It was found that four of the six sulfur atoms of the bigfoot derivative were adsorbed to gold. Further, it was found that no qualitative change in the XPS spectrum was apparent after the gold coated substrates with the bigfoot derivative adsorbed to the surface, were immersed in ethanol at 50° for 1 hour. In contrast, when this experiment was repeated replacing the bigfoot derivative with linker lipid A, approximately 30% of linker lipid A desorbed under these conditions.
The present invention provides compounds in which a spacer molecule is covalently incorporated into a linker lipid and/or linked to membrane spanning lipid. This serves several functions.
(A) The space between the hydrophilic chains of the reservoir linker lipid are defined by the size and structure of the binding site on the linker lipid and the packing of the linker lipid on the surface. Thus the spacing is not defined by the ratio of spacer to linker lipid as disclosed in WO 94/07593.
(B) The packing of the hydrophobic chains in the bilayer or monolayer membranes will also be influenced by the density of spacing of the linker lipids. This in turn can influence ionophore conductivity, ionophore diffusion or ionophore gating in the bilayer or monolayer membrane.
(C) There may exist substrates where, on binding of two species onto said substrate phase separation of the two species could occur leading to inhomogeneous distribution of the two species. This inhomogeneous distribution of spacer and linker lipid would in turn lead to inhomogeneous ion reservoir characteristics such as ion capacity or lateral resistivity. This would be avoided by use of the present invention.
(D) Increasing the number of binding interactions between the linker lipid and the substrate would lead to stronger binding between the substrate and the linker lipid and thus lead to a more stable biosensor membrane.
The use of a spacer molecule covalently linked to an ion channel serves the function of creating a space underneath the ion channel such that no other linker lipids can absorb underneath the ion channel. If the ion channel is significantly sterically crowded by other linker lipids then this may influence its ability to assume the appropriate conformation needed in order to form conducting channels. Additionally, the length of time that the channels exist in the open form may also be influenced by steric crowding of the linker lipid. Thus it may be useful for some applications to match the diameter of the binding group with the diameter of the ion channel.
In addition, the present invention provides molecules that include a covalently linked ionophore coupled onto the membrane spanning lipid or the linker lipid. The covalent attachment of the ionophore to the tethered linker lipid serves to prevent it from being removed out of the membrane, while the proper binding site size of the linker lipid ensures that the membrane and reservoir are spaced apart at the appropriate distance to allow proper ionophore conduction.
It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the spirit or scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive. | A linker lipid for use in attaching a membrane including a plurality of ionophores to an electrode and providing a space between the membrane and the electrode in which the membrane is either in part or totally made up of the linker lipid. The linker lipid has within the same molecule a hydrophobic region capable of spanning the membrane, an attachment group used to attach the molecule to an electrode surface, a hydrophilic region intermediate the hydrophobic region and the attachment group, and a polar head group region attached to the hydrophobic region at a site remote from the hydrophilic region. The attachment group has a cross sectional area greater than the cross sectional area of the hydrophilic region, and has the structure recited in the specification. | 85,676 |
TECHNICAL FIELD
[0001] The present invention relates to an electric parking brake device and, in particular, an electric parking brake device configured such that a parking lever in a drum brake is driven from a return position to an operating position by forward drive of an electric actuator to drive a brake shoe from a return position to an operating position and the parking lever is driven from the operating position to the return position by reverse drive of the electric actuator to drive the brake shoe from the operating position to the return position.
BACKGROUND ART
[0002] The electric parking brake device of this type is described in, for example, the following Patent Literature 1. A parking brake switch is actuated and operated to make it possible to drive an electric actuator forward and to make it possible to drive a parking lever from a return position to an operating position (more specifically, to set a parking brake in an operating state (lock state)). When the parking brake switch is operated to be released to make it possible to reversely drive the electric actuator and to make it possible to drive the parking lever from the operating position to the return position (more specifically, to set the parking brake in a release state (release state)).
CITATION LIST
Patent Literature
[0003] Patent Literature 1: Japanese Unexamined Patent Publication No. H11-105680
[0004] In the electric parking brake device described in the Patent Literature 1, an electric motor (motor) included in the electric actuator is rotated forward to make it possible to drive the electric actuator forward, and when a predetermined current or more flows in the forward-rotating electric motor, the electric motor is stopped to make it possible to always obtain a predetermined parking brake force. The Patent Literature 1 also describes that the electric motor (motor) included in the electric actuator is reversely rotated to make it possible to reversely drive the electric actuator, and, when a current flowing in the reversely rotating electric motor is a no-load current, a power supply to the electric motor is disconnected.
SUMMARY OF INVENTION
[0005] In the electric parking brake device described in the Patent Literature 1, depending on a current value flowing in the electric motor, an operation/stop state of the electric motor can be advantageously controlled (a sensor for electrically detecting the state of a parking lever is advantageously unnecessary). However, the brake shoe of the drum brake generally includes a return spring biasing the brake shoe toward the return position. For this reason, when the parking brake is released, the reverse drive of the electric actuator is assisted by the return spring.
[0006] Thus, a timing at which a current flowing in the reverse-rotating electric motor becomes a no-load current may be disadvantageously different from a timing at which the parking lever returns to the return position. For this reason, when the parking brake is released, the parking lever may be incompletely returned or excessively returned disadvantageously. When the parking lever is incompletely returned, for example, the brake is disadvantageously dragged. When the parking lever is excessively returned, for example, a drawback such as a delay of response in the next operation of the parking brake may occur.
[0007] The present invention has been made to solve the above problem (to prevent a parking lever from being incompletely returned or excessively returned in a release state of the parking brake), and has as its object to provide
[0008] an electric parking brake device configured such that a parking lever in a drum brake is driven from a return position to an operating position by forward drive of an electric actuator to drive a brake shoe from a return position to an operating position and the parking lever is driven from the operating position to the return position by reverse drive of the electric actuator to drive the brake shoe from the operating position to the return position, wherein
[0009] the electric actuator includes
[0010] an electric motor which can be rotationally driven forward/reversely and the operation of which can be controlled by a motor control unit depending on a rotational load,
[0011] a conversion mechanism which can convert rotational motion into linear motion, can move the parking lever from the return position to the operating position in a forward drive state in which the electric motor rotates forward, and can move the parking lever from the operating position to the return position in a reverse drive state in which the electric motor reversely rotates, and
[0012] a load applying mechanism drives a constituent member of the conversion mechanism after the parking lever moves from the operating position to the return position by reverse rotation of the electric motor to apply a rotational load increasing depending on a drive amount of the constituent member to the electric motor, and
[0013] the motor control unit includes a calculation unit which calculates a rotational load determination value to determine whether a rotational load applied to the electric motor by the load applying mechanism when the electric motor reversely rotationally drives is a set value or more on the basis of a current supplied to the electric motor, and a reversely rotational drive stop unit which stops the reversely rotational drive of the electric motor when the rotational load determination value is a reference value or more a set time after the reversely rotational drive of the electric motor is started.
[0014] In the electric parking brake device according to the present invention, the motor control unit can obtain a parking brake operation such that the electric motor is rotated forward by an actuating operation of the parking brake switch, and the forward-rotating electric motor is stopped by a current value obtained when a rotational load acting on the forward-rotating electric motor becomes a set value. At this time, when the parking brake switch is actuated and operated, the electric motor rotates forward, and the parking lever at the return position is driven from the return position to the operating position by forward drive of the electric actuator to drive a brake shoe from the return position to the operating position. At this time, since the device is set such that the forward-rotating electric motor is stopped by a current value (target current value) obtained when the rotational load (load obtained when the brake shoe moves to the operating position and is brought into press contact with the brake drum) acting on the forward rotating electric motor becomes the set value, predetermined parking brake force can be always obtained.
[0015] The motor control unit is set such that the electric motor is reversely rotated by a releasing operation of the parking brake switch, and the reversely rotating electric motor is stopped by a current value obtained when a rotational load acting on the reversely rotating electric motor becomes a set value, so as to make it possible to release the parking brake. At this time, when the parking brake switch is released, the electric motor reversely rotates, and the parking lever at the operating position is driven from the operating position to the return position by reverse drive of the electric actuator to drive the brake shoe from the operating position to the return position. At this time, since the device is set such that the reversely rotating electric motor is stopped by a current value obtained when the rotational load (load obtained by the load applying mechanism) acting on the reversely rotating electric motor becomes the set value, the parking lever can always be stopped in a state in which the parking lever is always returned to the predetermined return position.
[0016] Thus, in the electric parking brake device according to the present invention, the parking lever can be prevented from being incompletely returned or excessively returned when the parking brake is released. In this manner, a drawback (for example, drag of the brake) caused by incomplete return of the parking lever can be prevented, and a drawback caused by excessive return of the parking lever (for example, delay of response in the next operation of the parking brake) can be prevented.
[0017] In the electric parking brake device according to the present invention, the operation/stop of the electric motor can be advantageously controlled by a current value supplied to the electric motor (a sensor for electrically detecting the state of the parking lever is advantageously unnecessary), and the motor control unit can be simply configured at low costs. Since the motor control unit includes the calculation unit and the reversely rotational drive stop unit, the reversely rotational drive of the electric motor can be accurately stopped, and a rotational load required by the load applying mechanism can be set to be small. As a result, the load applying mechanism can be miniaturized and manufactured at low costs.
[0018] In execution of the present invention described above,
[0019] the rotational load determination value is a current value supplied to the electric motor, and a sum of a no-load current value detected in a reversely rotational drive state of the electric motor and a preset predetermined current value can also be defined as the reference value.
[0020] In this case, a sum of the no-load current value and the preset predetermined current value is defined as the reference value, and the no-load current value serves as a part of the reference value. For this reason, a fluctuation in performance caused by a manufacturing error or the like in the conversion mechanism or the load applying mechanism can be excluded. Thus, determination accuracy when the reversely rotational drive of the electric motor is stopped can be improved, and a rotational load required by the load applying mechanism can be reduced. As a result, the load applying mechanism can be miniaturized and manufactured at low costs.
[0021] In execution of the present invention described above,
[0022] the rotational load determination value is a differential value of a current value supplied to the electric motor, and the preset predetermined value can also be defined as the reference value.
[0023] In this case, since the rotational load determination value is the differential value of the current value supplied to the electric motor, in comparison with the case in which the sum of the no-load current value detected in the reversely rotational drive state of the electric motor and the preset predetermined current value is defined as the reference value, a stop timing can be more quickly determined. For this reason, determination accuracy when the reversely rotational drive of the electric motor can be improved, and the load applying mechanism can be further miniaturized and manufactured at low costs.
[0024] In each of the cases of the present invention,
[0025] the motor control unit can also include an abnormal-state reversely rotational drive stop unit which, when it is determined that the rotational load determination value is a reference value or more within the set time except for an operation initial time zone in which a current supplied to the electric motor is unstable from the start of the reversely rotational drive of the electric motor, stops the reversely rotational drive of the electric motor, and an abnormality notification unit which notifies of abnormality. In this case, the abnormal electric actuator in the device can be rapidly detected to stop the abnormal operation and to make it possible to notify of the abnormal operation.
BRIEF DESCRIPTION OF DRAWINGS
[0026] FIG. 1 is a perspective view showing an embodiment of an electric parking brake device according to the present invention.
[0027] FIG. 2 is a front view of the electric parking brake device shown in FIG. 1 .
[0028] FIG. 3 is a sectional view showing a configuration of an electric actuator in the electric parking brake device shown in FIG. 1 and FIG. 2 , and shows a cross-sectional plan view of a coupling part between a parking lever and a rod along 3 - 3 line in FIG. 4 .
[0029] FIG. 4 is a front view showing the parking lever and the rod shown in FIG. 3 and a coupling mechanism coupling the parking lever and the rod.
[0030] FIG. 5 is a flow chart showing a main routine executed by an electric control device shown in FIG. 3 .
[0031] FIG. 6 is a flow chart showing a sub-routine executed in a lock control process shown in FIG. 5 .
[0032] FIG. 7 is a flow chart showing a sub-routine executed in a release control process shown in FIG. 5 .
[0033] FIG. 8 is a flow chart showing a sub-routine executed in an in-abnormal-state process shown in FIG. 7 .
[0034] FIG. 9 is a flow chart showing a sub-routine executed in an in-normal-state process shown in FIG. 7 .
[0035] FIG. 10 is a graph showing a relationship between a time (time in which the electric motor reversely rotates) in which the sub-routines shown in FIG. 7 , FIG. 8 , and FIG. 9 are executed and a motor current (current supplied to the electric motor).
DESCRIPTION OF EMBODIMENTS
[0036] Embodiments of the present invention will be described below with reference to the accompanying drawings. FIG. 1 to FIG. 4 show an embodiment of an electric parking brake device according to the present invention. The electric parking brake device according to the embodiment includes a drum brake 10 having a parking brake mechanism and an electric actuator 20 driving the parking brake mechanism.
[0037] The drum brake 10 , as shown in FIG. 1 and FIG. 2 , includes a disk-like back plate 11 , one pair of brake shoes 12 and 13 assembled on the back plate 11 , an anchor block 14 , a wheel cylinder 15 , and the like. The back plate 11 is configured to be fixed to an attaching part (not shown) on a vehicle body side.
[0038] The brake shoes 12 and 13 are assembled on the back plate 11 such that the brake shoes 12 and 13 can move in a specific direction (direction along a plate plane) with reference to the back plate 11 , and integrally include arc-shaped linings 12 a and 13 a pressed against a brake drum (not shown) in a brake operating state, respectively. A coupling member 16 with adjustment mechanism and return springs S 1 and S 2 are assembled between the brake shoes 12 and 13 .
[0039] The brake shoe 12 on the left in FIG. 1 and FIG. 2 is configured to be engaged with a left piston (not shown) of the wheel cylinder 15 at an upper end of the brake shoe 12 , engaged with the anchor block 14 at the lower end, and pressed and spread to the left toward the brake drum (not shown) in a brake operation state. A parking lever 17 is swingably assembled on the brake shoe 12 .
[0040] On the other hand, the brake shoe 13 on the right in FIG. 1 and FIG. 2 is configured to be engaged with a right piston (not shown) of the wheel cylinder 15 at an upper end of the brake shoe 13 , engaged with the anchor block 14 at the lower end, and pressed and spread to the right toward the brake drum (not shown) in a brake operation state. A return spring S 3 (the spring S 3 has an upper end locked on the back plate 11 and a lower end locked on the brake shoe 13 ) is assembled on the brake shoe 13 .
[0041] The anchor block 14 is fixed to a lower part of the back plate 11 in the drawing by using one pair of fixtures 14 a and 14 b . The wheel cylinder 15 is fixed to an upper part of the back plate 11 in the drawing by using one pair of fixtures 15 a and 15 b . The wheel cylinder 15 includes one pair of pistons (not shown) which come away from the left and right sides in the operation of the brake to open the left and right brake shoes 12 and 13 , the wheel cylinder 15 housing the pair of pistons therein.
[0042] A coupling member 16 is tiltably engaged with an upper part of the brake shoe 12 at a left-end part and tiltably engaged with an upper part of the parking lever 17 , and tiltably engaged with an upper part of the brake shoe 13 at a right-end part. The coupling member 16 is configured to have a length which can be automatically adjusted (increasable) by a known adjustment mechanism 16 a depending on amounts of abrasion of the linings 12 a and 13 a.
[0043] The parking lever 17 is disposed along the left brake shoe 12 in the drawing and tiltably (rotatably) coupled to the brake shoe 12 at the upper-end part by using a pin 17 a and a clip 17 b . The parking lever 17 is configured such that the parking lever 17 , at the lower end, as shown in FIG. 3 , is engaged with a coupling mechanism 29 on the electric actuator 20 and driven in the left-right direction by the coupling mechanism 29 (rotatably driven around the pin 17 a ).
[0044] The electric actuator 20 , as shown in FIG. 1 and FIG. 2 , is disposed in the drum brake 10 . The electric actuator 20 , as shown in FIG. 3 , includes an electric motor 21 , a conversion mechanism 22 , and a stopper 27 and a disk spring assembly 28 which function as a load applying mechanism, and also includes the coupling mechanism 29 . The electric motor 21 can be rotationally driven forward/reversely, and is configured to be operated with a motor control unit (electric control device) ECU depending on a current value changing depending on a rotational load. The current value depending on the rotational load can be detected by a current monitor IM included in the motor control unit (electric control device) ECU.
[0045] The conversion mechanism 22 can convert rotational motion of the electric motor 21 into linear motion of a rod (screw shaft) 22 e (swinging operation of the parking lever 17 through the coupling mechanism 29 ), can axially move the rod 22 e from a return position (position in FIG. 3 ) to an operating position (position on the right of the position in FIG. 3 by a predetermined length) in a forward drive state in which the electric motor 21 rotates forward, and can axially move the rod 22 e from the operating position to the return position in a reverse drive state in which the electric motor 21 reversely rotates.
[0046] The conversion mechanism 22 includes a pinion 22 a integrally disposed on a rotating shaft 21 a of the electric motor 21 , a first intermediate gear 22 b 1 and a second intermediate gear 22 b 2 which are rotationally driven with the pinion 22 a , an output gear 22 c rotationally driven with the second intermediate gear 22 b 2 , a screw mechanism 22 d disposed at the center (center of axis) of the output gear 22 c , and the rod 22 e coupled to the output gear 22 c through the screw mechanism 22 d . The first intermediate gear 22 b 1 and the second intermediate gear 22 b 2 decrease rotation of the rotating shaft 21 a to transmit the rotation to the output gear 22 c.
[0047] The first intermediate gear 22 b 1 , the second intermediate gear 22 b 2 , and the output gear 22 c are rotatably assembled in a housing 22 g . A thrust bearing 22 h which receives reaction force (force to the left in FIG. 3 ) from the parking lever 17 is assembled between the output gear 22 c and the housing 22 g . The output gear 22 c is configured to be able to move in an axial direction with reference to the housing 22 g . The electric motor 21 and the housing 22 g are fixed to the back plate 11 by using a fixture (not shown).
[0048] The screw mechanism 22 d includes a female screw part formed at the center (center of axis) of the output gear 22 c and a male screw part formed from an intermediate part of the rod 22 e to the right end thereof, and the female screw part and the male screw part are meshed with each other. In the screw mechanism 22 d , when axial movement (movement to the left in the drawing) of the output gear 22 c is regulated, rotation (rotational motion) of the output gear 22 c is converted into axial movement (linear motion) of the rod 22 e . When axial movement (movement to the left in the drawing) of the rod 22 e is regulated by the stopper 27 , rotation (rotational motion) of the output gear 22 c is converted into axial movement of the output gear 22 c.
[0049] In the screw mechanism 22 d , leads of the female screw part and the male screw parts are arbitrarily set, and the output gear 22 c is set not to be rotated by reaction force (axial force) from the parking lever 17 . The male screw part formed on the rod 22 e is covered and protected with a boot 22 j disposed between the distal-end part (left-end part) of the rod 22 e and the housing 22 g . The boot 22 j is configured to extend and contract with the axial movement of the rod 22 e.
[0050] The stopper 27 and the disk spring assembly 28 which function as the load applying mechanism are designed to function after the parking lever 17 moves from the operating position to the return position, and the stopper 27 is fixed to the back plate 11 by using a fixture (not shown). The stopper 27 , after the parking lever 17 moves from the operating position to the return position, as shown FIG. 3 , is engaged with a first coupling pin 29 a of the coupling mechanism 29 to regulate axial movement of the rod 22 e in a return direction (to the left in the drawing).
[0051] By reverse rotation of the output gear 22 c with reverse rotation of the electric motor 21 , after the parking lever 17 moves from the operating position to the return position, in a state in which the first coupling pin 29 a is engaged with the stopper 27 to regulate the axial movement of the rod 22 e with the stopper 27 , when the output gear 22 c moves from the return position in an operating direction (to the right in the drawing) in FIG. 3 with the reverse rotation of the output gear 22 c , the disk spring assembly 28 is engaged with the right end of the output gear 22 c to elastically regulate the axial movement (movement to the right) of the output gear 22 c so as to apply a rotational load to the output gear 22 c . The rotational load described above increases depending on a drive amount (axial movement) of the output gear 22 c , and the rotational load applied to the electric motor 21 increases accordingly.
[0052] The disk spring assembly 28 , in the housing 22 g , is disposed coaxially with the output gear 22 c between the housing 22 g and the right end of the output gear 22 c . The disk spring assembly 28 includes a holder 28 a , three disk springs 28 b , and a thrust plate 28 c . The holder 28 a is to movably support the three disk springs 28 b and the thrust plate 28 c in a small-diameter cylindrical part, is disposed coaxially with the output gear 22 c , and is fixed to the housing 22 g in a large-diameter part.
[0053] The three disk springs 28 b are disposed between the large-diameter part of the holder 28 a and the thrust plate 28 c alternatively as shown in the drawing (such that the large-diameter parts contact with each other and the small-diameter parts contact with each other), and are almost freely disposed in the illustrated state. The thrust plate 28 c is disposed between the disk spring 28 b at the left end in the drawing and the right end of the output gear 22 c , and can rotatably bear the right end of the output gear 22 c . The thrust plate 28 c , at the position in FIG. 3 , is fixed to the small-diameter cylindrical part of the holder 28 a not to be removed therefrom (not to move to the left).
[0054] The coupling mechanism 29 , as shown in FIGS. 3 and 4 , includes the first coupling pin 29 a , a second coupling pin 29 b , and one pair of coupling plates (coupling members) 29 c . The first coupling pin 29 a is assembled on a distal end (end part) of the rod 22 e , orthogonal to the rod 22 e , and disposed in parallel with the pin (support shaft) 17 a of the parking lever 17 . An intermediate part of the first coupling pin 29 a is integrally fitted and fixed to an attaching hole 22 e 1 formed in the distal end (end part) of the rod 22 e . Both the end parts of the first coupling pin 29 a are assembled on first hole parts 29 c 1 each having an oval shape and formed in the coupling plates 29 c such that both the end parts can relatively rotate and move in a long-diameter direction (left-right direction in FIG. 3 and FIG. 4 ). When the rod 22 e returns and moves to the return position, as shown in FIG. 3 , both the end parts of the first coupling pin 29 a are set to be able to contact with the stopper 27 .
[0055] The second coupling pin 29 b is assembled on a swinging end part 17 c of the parking lever 17 and disposed in parallel with the first coupling pin 29 a . The second coupling pin 29 b is relatively rotatably assembled on a circular assembling hole 17 c 1 formed in the swinging end part 17 c at the intermediate part and relatively rotatably assembled on circular second hole parts 29 c 2 formed in coupling plates 29 c at both the end parts. The second coupling pin 29 b has both ends each having a diameter larger than that of the intermediate part to prevent the second coupling pin 29 b from being removed.
[0056] Each of the coupling plates 29 c can rotate in a first hole part 29 c 1 assembled in the first coupling pin 29 a in the circumferential direction of the first coupling pin 29 a with reference to the end part of the rod 22 e , can rotate in the second hole part 29 c 2 assembled in the second coupling pin 29 b in the circumferential direction of the second coupling pin 29 c 2 with reference to the parking lever 17 , and couples the first coupling pin 29 a and the second coupling pin 29 b to each other.
[0057] In the configuration, on the parking lever 17 and the rod 22 e coupled by the coupling mechanism 29 , a swinging surface of the parking lever 17 and an axial line of the rod 22 e are disposed on the same plane. For this reason, in the embodiment, driving force of the electric actuator 20 can be smoothly transmitted to the swinging end part 17 c of the parking lever 17 .
[0058] The motor control unit (electric control device) ECU, for example, has a function of stopping an operation (forward rotational drive) of the electric motor 21 when a rotational load reaches a set value (obtained by moving the parking lever 17 to the operating position) in a forward rotational drive state of the electric motor 21 , and a function of stopping an operation (reversely rotational drive) of the electric motor 21 when the rotational load reaches a predetermined value in a reversely rotational drive state of the electric motor 21 .
[0059] The motor control unit (electric control device) ECU is configured such that the motor control device ECU is also connected to a parking lock switch SW 1 and a parking release switch SW 2 (when any one of the switches is turned on, the other is turned off) which are disposed in the driver seat of the vehicle (see FIG. 3 ), and, as shown in FIG. 5 , when the parking lock switch SW 1 is turned on in a state in which a parking brake release state (release state) is stored, a lock control process in step 100 and an end process in step 99 are executed to end the program. When the parking release switch SW 2 is turned on in a state in which a parking brake operating state (lock state) is stored, a release control process in step 200 and the end process in step 99 are executed to end the program. The release state is configured to be stored when the reversely rotational drive of the electric motor 21 is normally completed, and the lock state is configured to be stored when the forward rotational drive of the electric motor 21 is normally completed.
[0060] When the motor control unit (electric control device) ECU executes the lock control process in step 100 in FIG. 5 , a lock control process routine in FIG. 6 is executed. In the lock control process routine in FIG. 6 , the process is started in step 101 , forward rotational drive of the electric motor 21 is started in step 102 , and an elapsed time T is counted up (Tup) in step 103 . In step 104 , it is determined whether the elapsed time T is a predetermined value T1 or longer. The predetermined value T1 corresponds to a time required until a current supplied to the electric motor 21 at the beginning of the forward rotational drive of the electric motor 21 becomes stable, and steps 103 and 104 are repeatedly executed until the elapsed time T reaches the predetermined value T1.
[0061] In this manner, when the elapsed time T reaches the predetermined value T1, step 105 is executed to determines whether a current value A (This is calculated on the basis of an output from the current monitor IM.) supplied to the electric motor 21 is a target current value A1 or more. The target current value A1 is obtained when the parking lever 17 moves from the return position to the operating position to make a rotational load (load obtained when the brake shoes 12 and 13 move to the operating positions to bring the linings 12 a and 13 a into press contact with the brake drum) obtained by the forward rotational drive of the electric motor 21 becomes a set value, and steps 105 and 106 are repeatedly executed until the current value A reaches the target current value A1. In step 106 , a condition establishment duration Ta is reset.
[0062] When the current value A reaches the target current value A1, steps 107 and 108 are executed to determine whether the condition establishment duration Ta is a predetermined value T2 or more. The predetermined value T2 is to determine a stop timing of the electric motor 21 , and is arbitrarily set. Steps 105 , 107 , and 108 are repeatedly executed until the condition establishment duration Ta reaches the predetermined value T2. When the condition establishment duration Ta reaches the predetermined value T2, “Yes” is determined in step 108 , steps 109 to 112 are executed to return the ECU to the main routine in FIG. 5 . The forward rotational drive of the electric motor 21 is stopped in step 109 , the lock state is stored in step 110 , and the elapsed time T and the condition establishment duration Ta are reset in step 111 . In step 112 , the return process is performed to end the program in step 99 in FIG. 5 .
[0063] On the other hand, when the motor control unit (electric control device) ECU executes the release control process in step 200 in FIG. 5 , a release control process routine in FIG. 7 is executed. In the release control process routine in FIG. 7 , the process is started in step 201 , reversely rotational drive of the electric motor 21 is started in step 202 , and the elapsed time T is counted up in step 203 . In step 204 , it is determined whether the elapsed time T is a predetermined value T3 or longer. The predetermined value T3 corresponds to a time required until a current supplied to the electric motor 21 at the beginning of the reversely rotational drive of the electric motor 21 becomes stable (see T3 in FIG. 10 ), and steps 203 and 204 are repeatedly executed until the elapsed time T reaches the predetermined value T3.
[0064] In this manner, when the elapsed time T reaches the predetermined value T3, step 205 is executed to determine whether the current value A supplied to the electric motor 21 is an abnormality determination current value A2 or more. The abnormality determination current value A2, for example, is obtained when rotational load obtained by the reversely rotational drive of the electric motor 21 is an abnormal value (see a virtual line and A2 in FIG. 10 ) when the parking lever 17 moves from the operating position to the return position (for example, an abnormally high rotational resistance is generated on the screw mechanism 22 d of the conversion mechanism 22 ). At this time, “Yes” is determined in step 205 to execute an in-abnormal-state process in step 210 .
[0065] When the motor control unit (electric control device) ECU executes the in-abnormal-state process in step 210 in FIG. 7 , an in-abnormal-state process routine in FIG. 8 is executed. In the in-abnormal-state process routine in FIG. 8 , the process is started in step 211 , and an abnormal condition establishment duration Tb is counted up (Tbup) in step 212 . In step 213 , it is determined whether the abnormal condition establishment duration Tb is a predetermined value T4 or more. The predetermined value T4 is to determine a stop timing of the electric motor 21 (see T4 in FIG. 10 ), and is arbitrarily set. Until the abnormal condition establishment duration Tb reaches the predetermined value T4, “No” is determined in step 213 , and step 205 in FIG. 7 and steps 211 to 213 in FIG. 8 are repeatedly executed.
[0066] When the abnormal condition establishment duration Tb reaches the predetermined value T4, “Yes” is determined in step 213 , and steps 214 to 217 are executed. The electric motor 21 is stopped in step 214 , an alarm for abnormality is generated in step 215 , and the elapsed time T and the abnormal condition establishment duration Tb are reset in step 215 . In step 217 , the return process is performed to end the program in step 99 in FIG. 5 .
[0067] In a period in which the elapsed time T falls within the range of the predetermined value T3 to a set value T5, when the current value A supplied to the electric motor 21 does not increase not to reach the abnormality determination current value A2 (more specifically, as indicated by a solid line or a broken line in FIG. 10 , when the electric motor 21 normally operates), steps 205 to 208 in FIG. 7 are repeatedly executed. “No” is determined in step 205 , the elapsed time T is counted up in step 206 , the abnormal condition establishment duration Tb is reset in step 207 , and “No” is determined in step 208 . The set value T5 is set on the basis of a time required when the parking lever 17 moves from the operating position to the return position by normal reversely rotational drive of the electric motor 21 .
[0068] In this manner, when the elapsed time T reaches the set value T5, “Yes” is determined in step 208 in FIG. 7 , and an in-normal-state process is executed in step 220 . When the motor control unit (electric control device) ECU executes the in-normal-state process in step 220 in FIG. 7 , an in-normal-state process routine in FIG. 9 is executed. In the in-normal-state process routine in FIG. 9 , the process is started in step 221 , a no-load current value Ao is calculated in step 222 , and it is determined in step 223 whether the current value A supplied to the electric motor 21 is a load determination current value (Ao+A3) or more. The no-load current value Ao is a current value supplied to the electric motor 21 before the first coupling pin 29 a is brought into contact with the stopper 27 by the reversely rotational drive of the electric motor 21 (more specifically, in a no-load state set until the first coupling pin 29 a contacts with the stopper 27 after the elapsed time T becomes the set value T5). A predetermined value A3 corresponds to a current value increasing depending on an increase in load obtained by the load applying mechanism (the stopper 27 and the disk spring assembly 28 ), and is arbitrarily set. Until the current value A reaches the load determination current value (Ao+A3), “No” is determined in step 223 , and steps 223 to 229 in FIG. 9 are repeatedly executed. In step 229 , a load condition establishment duration Tc is reset.
[0069] Until the current value A reaches the load determination current value (Ao+A3), “Yes” is determined in step 223 , and steps 224 to 225 are executed. The load condition establishment duration Tc is counted up in step 224 (Tcup), and it is determined in step 225 whether the load condition establishment duration Tc is a predetermined value T6 or more. The predetermined value T6 is to determine a stop timing of the electric motor 21 (see T6 in FIG. 10 ), and is arbitrarily set. Until the load condition establishment duration Tc reaches the predetermined value T6, “No” is determined in step 225 , and steps 223 to 225 are repeatedly executed.
[0070] When the load condition establishment duration Tc reaches the predetermined value T6, “Yes” is determined in step 225 , steps 226 to 228 are executed. The reversely rotational drive of the electric motor 21 is stopped in step 226 , the release state is stored and the elapsed time T and the load condition establishment duration Tc are reset in step 227 , and the return process is performed in step 228 to end the program in step 99 in FIG. 5 .
[0071] In the embodiment described above, although the determination is made by setting the durations Ta, Tb, and Tc to avoid an erroneous determination caused by signal noise or the like, the determination can also be made without setting the durations Ta, Tb, and Tc (executed such that, after T becomes T1, the forward rotational drive of the electric motor 21 is stopped when A reaches A1, the reversely rotational drive of the electric motor 21 is stopped when T is T3 to T5 and A reaches A2, and the reversely rotational drive of the electric motor 21 is stopped after T becomes T5 and when A reaches (Ao+A4)).
[0072] As described above, in short, in the embodiment, in the electric parking brake device according to the present invention, the operation/stop of the electric motor 21 can be advantageously controlled by a current value A supplied to the electric motor 21 (a sensor for electrically detecting the state of the parking lever 17 is advantageously unnecessary), and the motor control unit (electric control device) ECU can be simply configured at low costs. Since the motor control unit (electric control device) ECU includes the calculation unit (steps 222 and 223 ) and the reversely rotational drive stop unit (steps 223 to 226 ) and is configured to stop the reversely rotational drive of the electric motor 21 when it is determined that the rotational load determination value (current value A) is the reference value (Ao+A3) or more the set time after the reversely rotational drive of the electric motor 21 is started (T=0) (T≧T5), the reversely rotational drive of the electric motor 21 can be accurately stopped, and a rotational load required for the load applying mechanism (the stopper 27 and the disk spring assembly 28 ) can be set to be small. As a result, the load applying mechanism (the stopper 27 and the disk spring assembly 28 ) can be miniaturized and manufactured at low costs.
[0073] In the embodiment, the sum (Ao+A3) of the no-load current value Ao and the preset predetermined current value A3 is defined as a reference value for reversely rotational drive stop determination of the electric motor 21 , and the no-load current value Ao serves as a part of the reference value. For this reason, a fluctuation in performance caused by a manufacturing error or the like in the conversion mechanism 22 or the load applying mechanism (the stopper 27 and the disk spring assembly 28 ) can be excluded. Thus, determination accuracy when the reversely rotational drive of the electric motor 21 is stopped can be improved, and a rotational load required by the load applying mechanism (the stopper 27 and the disk spring assembly 28 ) can be reduced. As a result, the load applying mechanism (the stopper 27 and the disk spring assembly 28 ) can be miniaturized and manufactured at low costs.
[0074] In the embodiment, when it is determined that the rotational load determination value (current value A) is the reference value (A2) or more within the set time (time zone from T3 to T5) except for an operation initial time zone (time zone from 0 to T3) in which a current is unstable from the start of the reversely rotational drive (T=0) of the electric motor 21 , the abnormal-state reversely rotational drive stop unit (step 214 ) for stopping the reversely rotational drive of the electric motor 21 and the abnormality notification unit (step 215 ) for notifying of abnormality are included in the motor control unit (electric control device) ECU. For this reason, abnormality in the electric actuator 20 in the device is detected to make it possible to stop an abnormal operation and to notify of the abnormal operation.
[0075] In the embodiment, the program is executed such that the sum (Ao+A3) of the no-load current value Ao and the preset predetermined current value A3 is defined as the reference value for determining a timing of stopping the reversely rotational drive of the electric motor 21 and the current value A supplied to the electric motor 21 is defined as the rotational load determination value. However, in execution of the present invention, a differential value of the current value A supplied to the electric motor 21 may be employed as the rotational load determination value. In this case, the stop timing can be determined rapidly more than that in the embodiment, determination accuracy at which the reversely rotational drive of the electric motor 21 is stopped can be improved, and the load applying mechanism can be further miniaturized and manufactured at low costs.
[0076] In the embodiment, the determination is made such that the sum (Ao+A3) of the no-load current value Ao and the preset predetermined current value A3 is defined as the reference value for determining a timing of stopping the reversely rotational drive of the electric motor 21 and the current value A supplied to the electric motor 21 is defined as the rotational load determination value. However, in execution of the present invention, the determination can also be made such that the set value A4 (see FIG. 10 ) larger than (Ao+A3) is employed as the reference value.
[0077] In the embodiment, an abnormality determination is made by the current value A supplied to the electric motor 21 . However, for example, the abnormality determination can also be made by a differential value of the current value A supplied to the electric motor 21 , and various changes can be effected without departing from the contents described in the scope of claims. | Electric parking brake devices are configured such that a parking lever is driven by an electric actuator. The electric actuator is provided with: an electric motor drivable in a forward/reverse direction and operationally controlled by a motor control unit according to rotational loads; a conversion mechanism capable of converting a rotational motion into a linear motion, moving the parking lever from a return position toward an operating position through forward rotation of the electric motor, and moving the parking lever from the operating position toward the return position through the reverse rotation of the electric motor; and a load applying mechanism (a stopper and a disc spring assembly) for applying a predetermined rotational load to the electric motor by driving a constituent member of the conversion mechanism after the parking lever is moved from the operating position to the return position through the reverse rotation of the electric motor. | 44,087 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to molecular biology and clinical diagnostics, specifically to methods, devices, and compositions for fractionation and processing of microparticles from biological samples, and to methods for obtaining and using the microparticles for biomarker discovery. Biological samples include cell-free fluids, for example blood plasma, blood serum, cerebrospinal fluid, urine, and saliva, as well as conditioned media. Conditioned media is the liquid growth media used to propagate cells in vitro. Purification of microparticles from cell-free fluids is challenging, typically accomplished by prolonged ultracentrifugation. We have developed an alternative method for efficiently harvesting and processing microparticles from cell-free fluids and from conditioned media. The invention also generally relates to use of the microparticles and their contents recovered from conditioned media derived from propagation of human and animal cells, as a source of biomarkers for diagnosis and prognosis of diseases and pathological conditions.
[0003] 2. Description of the Relevant Art
[0004] There is a growing appreciation of the biological role of different types of membrane-bound microparticles (MPs) shed by cells and tissues. As used in this application, the term “microparticles” refers to all types of membrane-bound particles released by cells and platelets, including microvesicles, microparticles, tumor microvesicles, exosomes, ectosomes, platelet dust, apoptotic bodies, etc. These particles, which may be roughly spherical or irregular in shape, differ according to size and origin, for example apoptotic bodies range in size from one to several micrometers and are shed from cells undergoing apoptosis (the process of “programmed cell death”), while microvesicles, which are smaller than 1 μm, are thought to bud off directly from the plasma membrane of healthy cells. Exosomes are even smaller, on the order of 30-100 nanometers (nm), and are released from multivesicular bodies by the process of exocytosis. The distinction between different types of MPs is not always clear. For example the term apoptotic bodies has been used synonymously with microparticles.
[0005] MPs contain integral membrane proteins reflecting their cells of origin, and bioactive molecules including mRNA, microRNA and proteins. Many recent publications describe between-cell delivery of biological signals mediated by proteins and RNA contained in MPs (see above references). MPs are thought to be produced by all or most types of cells and tissues. MPs shed from cells and solid tissues can enter the circulation and occur in cell-free fluids, for example in the non-cellular fraction of blood known as plasma or serum. MPs are also shed in abundance into conditioned media, which is the media used to propagate cells in vitro, including eukaryotic and prokaryotic cells, mammalian cells, and especially including human cells. Large quantities of MPs are shed into conditioned media from malignant cells, from which the shedding of MPs may be increased compared to non-malignant cells. MPs shed from tumors may enter the circulation and mediate growth of tumors, for example by inducing growth of blood vessels that deliver nutrients to support tumor growth. MPs detected in the circulating blood of cancer patients are potential sources of diagnostic and prognostic biomarkers. Current research is focused on gaining a better understanding of the role of MPs in delivery of biological signals between cells and tissues, in both disease and health, and in identifying MP-based biomarkers. Improved methods for concentrating MPs from conditioned media and from cell-free body fluids will allow samples to be processed more rapidly and at a lower cost. This will permit detection of low-abundance MP-derived analytes, including RNAs and proteins, and increase the sensitivity of assays aimed at quantitative detection of MPs for clinical purposes, including biomarker discovery. The term “biomarkers” refers to molecules of biological origin (for example RNA, DNA, and proteins) derived from patient samples, whose levels have diagnostic and/or prognostic value.
[0006] A limitation in MP-based research is that current methods for recovering these particles from the relatively large volumes of fluids in which they occur, are laborious, time-consuming, and require expensive specialized equipment. The currently used methods for concentrating MPs from blood or culture media involve sequential centrifugation of liquid samples at increasing relative centrifugal force (rcf) to first remove intact cells and larger cell fragments and debris by low-speed centrifugation, followed by centrifugation at higher rcf to pellet the particles of interest. The rcf used to recover particles varies according to their size. For example, in one study, conditioned media was centrifuged for 10 min at 800×g to remove dead cells and cell debris, then further centrifuged for 20 min at 16,000×g to pellet the relatively large apoptotic bodies. In another study, microvesicles shed by cultured tumor cells were isolated by centrifuging the culture media for 30 min at 2,000 rpm to remove cell debris, followed by centrifugation at 20,000 rpm for 2 hours to pellet the MPs. To recover smaller particles, even higher ref is required, for example one study showed that for isolation of microvesicles it is widely accepted that ultracentrifugation should be performed at 100,000×g from 20-60 minutes and that in order to recover MPs smaller than 100 nm (the so-called exosomes), sucrose gradient ultracentrifugation is required.
[0007] Concentrating MPs by centrifugation requires expensive equipment. For example Beckman ultracentrifuges retail for around $60,000-$70,000 and the rotors required for their use list for $20,000-$23,000. Such equipment is not routinely available, especially in clinical labs and small research labs. These considerations argue for the need for better methods to facilitate processing of liquid samples to purify MPs. Once this hurdle has been passed, rapid gains can be expected in basic and applied research needed to exploit the use of MPs for therapeutic and diagnostic applications. The invention described herein overcomes the requirement for sequential centrifugation and for ultracentrifugation to purify MPs. The invention further describes the use of MPs from conditioned media for discovery of biomarkers. The biomarkers will enable use of MPs produced by patient cells propagated in vitro for improved diagnosis and treatment of disease.
[0008] Several research groups have reported identification of candidate biomarkers in RNA, microRNA, or proteins extracted from MPs present in human cell-free bodily fluids, especially blood plasma and serum. However, size-fractionated MPs recovered from conditioned media from patients' cultured cells have not been described as source of biomarkers. A major technical advantage of identifying RNA biomarkers in MPs compared to using solid tissues or circulating blood cells or cells cultured in vitro as the source tissue, is that RNA in MPs is expected to be much more stable in the transcriptionally inactive particles shed from cells (MPs), compared to their status in metabolically active tissues and cells, where rapid up-and down-regulation of specific RNA levels has been well-documented. Also, RNA in MPs is protected from the nucleases present in high concentrations in conditioned media and in cell-free body fluids such as blood plasma and urine. The potential of MPs to serve as biomarkers and potentially also as therapeutic agents will require considerable basic research followed by major development efforts to translate new findings into clinical assays and products. An important first step toward this goal is to create methods that allow rapid, economical, high-yield purification of MPs and their contents, especially RNA and proteins.
[0009] In light of the above considerations and notwithstanding the acknowledged ambiguity in the nomenclature used to describe the various types and origins of cell-derived microparticles, it can be reasonably concluded that MPs can be classified according to size into at least 3 categories: a. MPs greater than approximately 1 micron in diameter (for example apoptotic bodies); b. MPs smaller than 1 micron but larger than approximately 0.1 micron in diameter (for example microvesicles); c. MPs smaller than 0.1 micron in diameter (for example exosomes); and further, that MPs can be fractionated from fluids containing mixtures of different types of MPs by sequential centrifugation of the fluids at increasing centrifugal forces of approximately 800-2,000×g, 16,000-20,000×g, and 80,000-100,000×g. Further, MPs can be recovered from primary and long-term in vitro cultures of mammalian cells, including human cells. “Primary” cell cultures are those in which the cells originated from living tissues removed from an animal, whereas long-term cultures relate to populations of cells surviving after the primary culture has been “passaged” many times. “Passaging” cultured cells means removing a subset of growing cells, typically along with some of the conditioned media in which they have been growing, and transferring them to a new vessel, along with fresh culture media; after transfer, the cells continue to grow and divide (a process known as “expansion”). Typically, after a set number of passages, many of the primary cells and their progeny undergo the process of senescence, meaning they fail to continue to divide; however, a relatively few minority of cells may survive senescence and continue to grow and divide, thus establishing a long-term immortal cell line derived from a particular primary culture. Examples of tissues used as source of primary cells for in vitro culture are cells from solid tumors or malignancies of the blood, as well as healthy tissues including blood, endothelial cells, skin fibroblasts, epithelial tissue, etc.
[0010] MPs isolated from conditioned media from primary and/or long-term culture of a patient's cells have potential to serve as source of biomarkers. When the primary cells are pathological in origin, the MPs may serve as a source for clinically useful biomarkers for diagnosis and/or treatment of the pathological condition, for example, malignancy. It is contemplated that MPs can be harvested from conditioned media obtained from primary and/or long-term culture of an individual's cells, and that contents of the MPs, including RNA, microRNA, and proteins, can be extracted from the MPs to provide clinically useful information. It is further contemplated that the information content of the MPs will be more useful when the naturally occurring heterogeneous mixtures of MPs are first fractionated according to size, prior to extracting their contents for analysis. It is further contemplated that analysis of contents of MPs fractionated according to size will improve the ability to discover MP-derived biomarkers and apply them for clinical use.
[0011] Many experimental approaches are contemplated for biomarker discovery and use in MPs obtained from conditioned media. One approach is comparison of the levels of biomolecules in MPs derived from patient samples, with the levels of the same biomolecules derived from healthy individuals. Another approach is investigation of MP content in temporal space, which may itself consist of at least 2 types. One type of temporal analysis is analysis of MPs from conditioned media collected over a time-course, for example collected after shorter and longer periods of culture of primary cells derived from a patient's tumor. Another type of temporal analysis is analysis of MPs from primary cells obtained from tissues harvested sequentially at different times during the course of disease, for example from a needle biopsy of a newly-diagnosed malignancy and from a subsequent biopsy of a tumor from the same patient after treatment. Analysis of sequential MP samples from conditioned media samples obtained over temporal space is expected to lead to identification of associative patterns that can be developed into clinically useful biomarkers. Another approach for biomarker discovery in MPs harvested from conditioned media is to compare contents of MPs recovered from cells of different lineages, for example malignant tumor cells, endothelial cells, or blood leukocytes, that may grow out of a single tissue isolate. Yet another approach for MP-based biomarker discovery and use is to analyze MPs recovered from experimentally treated cells, for example cells treated to induce apoptosis. One of the most straightforward treatments of cultured cells to induce apoptosis is to grow them under “serum starvation” conditions, that is, in media from which the usual component of fetal bovine serum (typically added to basic liquid growth media to a level of ˜10%-20%) is withheld. These approaches are not mutually exclusive and can be combined. For example, one could carry out temporal analysis of MPs recovered from conditioned media from treated cells of several lineages derived from a single tumor. For all of these approaches, the promise of identifying new biomarkers for clinical use will be more easily realized by using size-fractionated MPs, rather than using complex mixtures of MPs of divergent sizes (which reflect their divergent biological origins). Better methods to fractionate and process conditioned media-derived MPs will facilitate MP-related basic research, leading to significant clinical benefits. The present disclosure overcomes current limitations in obtaining and processing size-fractionated MPs from heterogeneous samples.
SUMMARY OF THE INVENTION
[0012] In one embodiment, a method for concentrating and fractionating microparticles according to their size from a liquid sample, comprises passing the sample sequentially through at least two filters having different pore sizes, wherein said filters are effective to trap membrane-bound particles of different sizes from the liquid sample. The filters may be contained in devices having inlet and outlet ports such that the devices can be attached to each other and to standard syringe(s). One or more of the filters may include a pre-filter effective to remove debris from the liquid sample which could otherwise interfere with entrapment of the membrane-bound particles.
[0013] In one embodiment, a sample is passed through a first filter having a pore size effective to trap larger particles from the liquid sample, and subsequently passed through one or more additional filters having pore size(s) effective to trap particles smaller than the larger particles from the liquid sample. The first filter may have has a pore size of about 200 nanometers (nm) and one or more of the additional filter has a pore size of about 20 nm. In another embodiment, the first filter has a pore size of about 700 nm-1,000 nm, a second filter has a pore size of about 200 nanometers (nm), and a third filter has a pore size of about 20 nm.
[0014] In an embodiment, the filters are attached to each other prior to passing the liquid sample through them, such that the sample passes through a first filter and then through one of more additional filters. The filters may be separated after passing the liquid sample through them. The separated filters with trapped particles may be processed to extract the contents of the particles. In one embodiment, the process of extracting the contents of the particles includes: passing a reagent through the separated filters, said reagent having a composition effective to disrupt the membranes of the trapped particles, thereby forming a particle lysate; collecting the particle lysate; and treating the particle lysate in a manner to purify and concentrate one or more biological components present in said lysate. Biological components that may be extracted include RNA, DNS, proteins, or combinations thereof.
[0015] In one embodiment, a method for identifying biomarkers having clinical utility for diagnosis and/or treatment of disease includes: obtaining two or more samples of tissue or cells; treating and maintaining the samples under conditions effective to allow in vitro propagation of cells in said samples in a liquid medium; recovering the liquid medium used to propagate the cells from the samples; processing the liquid medium from the samples using filters to recover membrane-bound particles present in the samples; purifying one or more biological components from particles retained on the filters from the samples; determining the levels of one or more purified biological components from the samples; comparing the levels of one or more of the purified biological components recovered from one or more samples between said samples; and determining associations between compared levels of one or more of the purified biological components recovered from one or more samples, where said associations have correlations with different physiological conditions in the one or more samples. The biological component being compared may be RNA (e.g., microRNA), DNA, proteins, or combinations thereof.
[0016] In one embodiment, a method for obtaining diagnostic or prognostic information for clinical use includes: obtaining a sample of tissue or cells from an individual; treating and maintaining the sample under conditions effective to allow in vitro propagation of cells in said samples in a liquid medium; recovering the liquid medium used to propagate the cells from the sample; processing the liquid medium from the sample using filters to recover membrane-bound particles present in the samples; purifying one or more biological components from particles retained on the filter from the sample; determining the levels of one or more purified biological components from the sample; and analyzing the levels of one or more of the purified biological components recovered from the sample to determine associations between said levels and known expected values of said components, said analysis effective to provide prognostic or diagnostic information relevant to the individual.
[0017] In one embodiment, a method for obtaining diagnostic or prognostic information for clinical use includes: obtaining a sample of cell-free bodily fluid from an individual; processing the fluid using filters to recover membrane-bound particles present in the fluid; purifying one or more biological components from particles retained on the filter from the sample; determining the levels of one or more purified biological components from the sample; and analyzing the levels of one or more of the purified biological components recovered from the sample to determine associations between said levels and known expected values of said components, said analysis effective to provide prognostic or diagnostic information relevant to the individual.
[0018] In one embodiment, a kit for fractionating MPs from biological samples, includes one or more filters and devices effective to capture said MPs from the samples, and optionally also comprising reagents for extracting, concentrating, and purifying the contents of said MPs.
[0019] In one embodiment, a method for preparing lipids and/or lipid-containing material from MPs includes: concentrating and fractionating microparticles according to their size from a liquid sample; treating the fractionated microparticles with reagent(s) effective to disrupt and solubilize their membranes; and recovering the disrupted and solubilized membrane components. The disrupted and solubilized membrane components may be further purified by treatment with nucleases and/or proteases and/or treated to remove solvents or detergents.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Advantages of the present invention will become apparent to those skilled in the art with the benefit of the following detailed description of embodiments and upon reference to the accompanying drawings in which:
[0021] FIG. 1 depicts an analysis of RNA extracted from MPs trapped on filters.
[0022] While the invention may be susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. The drawings may not be to scale. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but to the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] It is to be understood the present invention is not limited to particular devices or biological systems, which may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting. As used in this specification and the appended claims, the singular forms “a”, “an”, and “the” include singular and plural referents unless the content clearly dictates otherwise.
[0024] Described herein are methods, devices and reagents for fractionating and purifying microparticles (MPs) and their contents from biological samples. A primary feature of the embodiments described herein are the use of a series of filters having suitable properties for trapping MPs of different sizes from biological samples, and devices to allow use of such filters for recovering MPs from biological samples. Examples of biological samples that may be used with said filters and devices are blood serum and blood plasma from humans and other mammalian and non-mammalian animals, as well as conditioned media used to propagate cells in culture. The MPs captured on the filters may subsequently be recovered from the filters as intact particles, said particles having potential for use as delivery agents for transferring their contents to recipient cells. Contents of potential interest that may be transferred by intact MPs are proteins, chemicals, DNA, mRNAs, microRNAs, siRNAs, and other non-coding RNAs.
[0025] As an alternative to recovering intact MPs from the filters for use as delivery agents, the MPs captured on the filters may be processed by disrupting the MPs and collecting their contents. Disruption of captured MPs may be accomplished by removing the filters along with the trapped MPs to a second vessel, for example a microfuge tube, and adding reagent(s) capable of disrupting the MP membrane and releasing its contents. Alternatively, recovery of the MP contents may be accomplished by in situ disruption of the MP's membranes without removing the filters from the device in which they are placed, for example by flushing the filters with reagent(s) effective to disrupt the captured MPs and release their contents into a separate vessel. Disruption of MPs can be accomplished by use of various reagents. For disruption of MPs and subsequent purification of their RNA and/or protein contents, single-phase reagents containing chaotropic agent(s) (such as guanidinium thiocyanate or guanidinium hydrochloride) and organic solvent (such as phenol) are especially useful. Alternative reagents such as those based on other denaturing chemicals such as urea, or on other nuclease-inactivating reagents such as proteases, may be used instead of single-phase reagents containing guanidinium and phenol. Other types of membrane-disrupting reagents familiar to those skilled in the art of molecular biology may also be used to disrupt the MPs. Further purification and concentration of the contents of disrupted MPs can be accomplished using a variety of different methods known to those skilled in the art, for example alcohol precipitation or solid-phase extraction onto silica matrices. An aspect of the process includes the use of reagents and protocols for further purifying and concentrating the contents of MPs trapped on filters. A further aspect of the process relates to use of biomolecules recovered from MPs released by cells, especially those grown in vitro, as a source for discovery of biomarkers and as source sample for use of said biomarkers for diagnosis and prognosis of pathological conditions.
[0026] In addition to recovering and using the contents of disrupted MPs, it is contemplated that recovery of the lipid monomers and other lipid-containing materials originating from the disrupted membranes of MPs, may also be useful. Such lipids or lipid-containing materials could be recovered by solubilizing the MPs in solvents such as chloroform or by disrupting the MPs in reagents containing detergents. The solvents or detergents can then be removed, for example by evaporation or by chromatography, leaving the lipids and lipid-containing materials in a more concentrated foam. It is contemplated that such lipids and lipid-containing materials will be useful for preparing liposomes for delivery of natural or synthetic molecules, especially for clinical purposes. Examples of synthetic molecules that may be delivered by MP-derived liposomes and that have utility for clinical purposes are small interfering RNA molecules (siRNAs) and synthetic DNA molecules that may encode siRNAs, and recombinant viral vectors. Examples of natural molecules that may be delivered by MP-derived liposomes and that have utility for clinical purposes are plasmids, viruses, and antibodies. Natural and synthetic molecules may be incorporated into the liposome membranes and/or into the interior space of the liposomes. In cases where it is desirable to recover lipids or lipid-containing materials derived from membranes of MPs in a substantially pure form wherein the lipids or lipid-containing materials are not mixed with the contents of the MPs, the contents of the MPs can be removed or rendered inactive by disrupting the MPs, or by treating the material comprising disrupted MPs, with reagents containing nucleases, including DNases and RNases, and/or by treating or disrupting the MPs with reagents containing proteases.
[0027] In one embodiment, a process uses filtration, instead of the currently used method of centrifugation, to directly capture MPs from liquid samples. In an embodiment, a series of two or more filters having different properties are used to allow entrapment of MPs of different sizes. Liquid samples containing mixtures of MPs that differ in their origin, sizes, and contents, may be recovered as separate populations for further analysis. In one embodiment, the filters are contained in plastic devices that provide support for the filters and that allow attachment of the filters to a reservoir that is used to contain the liquid sample prior to processing. An especially useful design for such devices is as so-called “syringe filters”, in which filters are placed over a perforated support to allow liquid to flow through the filter, and with the device having inlet and outlet ports designed such that the devices can be readily connected to each other and to standard syringes. The syringes can be of different sizes, ranging from less than 1 ml to 60 ml, to allow processing of samples of a wide range of volumes. For cases in which two or more syringe filter devices are connected to each other, they are connected such that the top filter, that is the filter in which the liquid sample is first contacted, has the largest effective pore size, enabling entrapment of the largest particles, and subsequent filters are in order of decreasing pore size, to enable successive entrapment of smaller and smaller particles. The top filter in a series of connected filters may have a pore size of >1 μM, effective to trap intact cells with minimal entrapment of smaller microparticles. To maximize recovery and size homogeneity of MPs, a liquid sample may be passed over a series of 2 or more filters, or over a single filter, and the “flow-through” liquid passing through the filter(s) may be recovered and passed once again over the same filter(s). After the liquid sample has been passed over a series of one or more filters, the filters are then disconnected and processed separately, to allow recovery of the size-fractionated MPs or their contents as separate preparations.
[0028] In one process, filters are used to harvest MPs from cells grown in tissue culture. Different types of mammalian cells are known to naturally shed MPs into the culture media. As discussed above, these MPs can serve as a source of biomarkers. Those skilled in the art of molecular biology will also appreciate that primary cells or immortalized cell lines can be engineered, using methods known to those with skill in the art, to make MPs with useful RNA and/or protein content.
[0029] The following examples are included to demonstrate preferred embodiments of the invention. It should be appreciated by those of skill in the art that the techniques disclosed in the examples which follow represent techniques discovered by the inventor to function well in the practice of the invention, and thus can be considered to constitute preferred modes for its practice. However, those of skill in the art should, in light of the present disclosure, appreciate that many changes can be made in the specific embodiments which are disclosed and still obtain a like or similar result without departing from the spirit and scope of the invention.
Example 1
Fractionation of Populations of Smaller and Larger MPs from Tissue Culture Media
[0030] Conditioned media was obtained from several human cancer cell lines (A549 lung cancer, CLL lymphoma cells, and HL60 liver cancer cells) growing as adherent cells, that is, the cells were attached to the bottom of the culture vessels. Typical volumes of conditioned media from adherent cells range from about 5 ml-15 ml per 100 mm tissue culture dish. In general, the conditioned media may be loaded into a syringe of appropriate capacity for the volume of sample, by aspirating the media into the syringe. Syringe filters having pore sizes effective to trap MPs from the conditioned media are then attached to the outlet port of the syringe. Alternatively, the plunger of the syringe may be removed, the syringe filter(s) then attached, and the conditioned media then loaded by pouring it into the barrel of the syringe and then reinserting the plunger. In either case, the end result is a syringe containing the conditioned media, with the filter(s) attached. The latter option for loading the sample into a 12 ml syringe was used in this Example.
[0031] The filters used in this Example consist of two syringe filters, each ˜25 mm in diameter, with the top filter having a pore size of ˜200 nanometers (0.2 microns), and the bottom filter having a pore size of ˜20 nanometers (0.02 microns). The syringe filters were obtained from Tisch Scientific (Village of Cleves, Ohio 45002, USA). The filter having a pore size of ˜200 nanometers was catalog #SF14499, and the filter having a pore size of ˜20 nanometers was catalog #SF15016. The syringe filter-syringe assembly was then positioned over a vessel to catch the flow-through. The plunger of the syringe was then gently depressed to apply the force needed to drive the media sample through the connected filters. After the sample had passed through the filters, they were removed from the syringe and then disconnected from each other. Residual media in the filter devices was removed by tapping the outlet ports of the devices on a paper towel. Each of the filter devices were separately processed by attaching each to a 6 ml syringe which had been preloaded with 1 ml of a single-phase reagent (BiooPure RNA Extraction Reagent, Bioo Scientific, Austin, Tex.) comprising phenol, guanidinium thiocyanate, and other components effective to disrupt cell membranes, including the membranes that delineate cellular MPs. The assemblies were positioned over 1.5 ml microcentrifuge tubes, and the plungers of the syringes slowly depressed to force the BiooPure reagent into the filter device. The assembly was tilted during delivery of the BiooPure reagent into the filter device, in order to maximize contact of the reagent with the surface of the filter. Contact of the reagent with the entire surface of the filter is confirmed visually, by presence of green color on the entire surface of the filter. Contact of the reagent with the trapped MPs causes their membranes to be disrupted, resulting in release of their contents. The plungers were then fully depressed to flush the reagent, along with the contents of the disrupted MPs, into 1.5 ml receiving tubes. The samples (lysates from size-fractionated MPs) were then mixed thoroughly by vortexing. Samples may be processed immediately to purify and concentrate the released contents of the MPs, or the samples may be stored for subsequent processing. In this Example, the samples were stored at −20 C. for several days prior to further processing.
Example 2
Extraction of RNA from MPs Recovered from Conditioned Media
[0032] Extraction of RNA from MPs was carried out using a proprietary reagent (BiooPure RNA Extraction Reagent) developed at Bioo Scientific, which is similar to Trizol (sold by Sigma and other vendors). Trizol has also been used for extraction of MPs captured from conditioned media on filters. Trizol and BiooPure are both single-phase reagents containing phenol and guanidinium, and the extraction protocols are similar. RNA was extracted by thawing the preparations (described in Example 1) and adding 0.1 ml of 1-bromo-3-chloropropane (purchased from Sigma Life Science Research products, cat #B9673), vortexing the prep for ˜20 sec, then centrifuging the prep in a microcentrifuge for ˜15 min at 4 C. The resulting separated aqueous phase (top phase) was transferred to a new 1.5 ml tube and mixed with 50 μg of linear polyacrylamide (Bioo Scientific), followed by mixing with 0.75 ml of isopropyl alcohol. The prep was stored at room temp for ˜15 min and then centrifuged for 15 min at 12,000 rpm at 4 C. The supernatant fluid was carefully removed and the pelleted material was washed by adding 0.6 ml of 75% ethanol (diluted in nuclease-free water), vortexing to dislodge the pellet, then re-centrifuging the prep for 10 min at 10,000 rpm at 4 C. The supernatant fluid was thoroughly removed and the pellet of RNA dissolved in 50 μL of 0.1 mM EDTA made in nuclease-free water. To aid solubilization, the prep was vortexed, then incubated for 5 min at 65 C. in a heat block, then re-vortexed and centrifuged briefly to collect all liquid at the bottom of the tube. The preparation was then stored at −20 C. until use.
Example 3
Quantitative Detection of microRNAs in RNA Extracted from Size-Fractionated MPs Recovered from Conditioned Media
[0033] Recovery of RNA from the MPs captured on filters from conditioned media was verified by using a commercially available microRNA-detection assay from Life Technologies Inc. This assay is based on reverse transcription followed by quantitative PCR(RT-qPCR). We have also used this assay to detect microRNA in preps from MPs recovered from human serum.
[0034] The reverse transcription step was carried out in a 7.5 μL volume containing 2.5 μL of RNA prepared as described in Example 2 along with approximately 50 units of MMLV Reverse Transcriptase (Bioo Scientific), standard buffer components, and reverse transcription primers for several microRNAs (miR-150, miR-191, and miR-337), provided in the Life Technologies assays. Reactions were incubated according to the Life Technolgies protocol. For the qPCR step, 1.5 μL of each reverse transcription reaction was used as template for duplicate amplification reactions (“technical duplicates”) of 20 μL, using the microRNA target-specific amplification primers from the Life Technologies assay according to manufacturer's instructions. Reactions were carried out using a BioRad iQ real-time instrument and Ct values recorded. Ct stands for cycle threshold, the amplification cycle number at which a detectable fluorescent signal is generated over a preset background level; in this study the instrument default value was used for the background and detection settings. The lower the Ct value, the higher the abundance of target molecule in the sample (since the more abundant the target, the fewer PCR cycles are needed to amplify it to a detectable level). Due to the exponential nature of PCR, a difference of 3.32 Ct's corresponds to a ˜10-fold difference in target abundance (since 2̂3.32˜10). We observed the following data in this experiment:
[0000] Sample RNA miR-150 Ct value miR-191 Ct value miR-337 Ct value RNA recovered from Technical duplicates: Technical duplicates: Technical duplicates: MPs trapped on top 29.76/29.69, 24.62/24.63 32.07/32.39 filter having larger avg = 29.72 Avg = 24.62 Avg = 32.23 pore size RNA recovered from Technical duplicates: Technical duplicates: Technical duplicates: MPs trapped on 28.22/27.91 27.69/26.63 31.81/31.95 bottom filter having Avg = 28.07 Avg = 27.16 Avg = 31.88 smaller pore size Negative control (no Not detected (Ct > 45) Not detected (Ct > 45) Not detected (Ct > 45) input cDNA in PCR step)
This experiment demonstrates the effectiveness of the filters for concentrating microRNA from conditioned media. Since the relative levels of specific microRNAs in fractionated MPs obtained from conditioned media have not been reported previously, there is no basis for comparison of our results to those of others. However this experiment indicates that the filters trapped different populations of MPs, because the relative levels of the 3 microRNAs differed in the MPs trapped on the filter with larger pore size compared to the filter having smaller pore size. The level of miR-191 is ˜34-fold higher than miR-150 in MPs captured on the filter with larger pore size (2̂5.1), while the level of miR-191 is only ˜1.9 fold higher than miR-150 in MPs captured on the filter with smaller pore size (2̂0.91).
Example 4
Fractionation and Processing of MPs from Human Serum
[0035] Human blood serum was purchased from a commercial source (Innovative Research) and approximately 5 ml of serum from a single donor was fractionated over a filter having a 20 nm pore size as described in Example 1. The filter was then flushed with RNA extraction reagent to lyse the trapped particles as described in Example 2; the lysate was recovered and saved for RNA extraction. This sample is referred to as “Serum filter”. Prior to filtration, 0.25 ml of serum was removed and mixed with RNA extraction reagent as described in Example 2 (this sample is referred to as “pre-filtration serum”). After filtration, 0.25 ml of serum that had passed through the filter was removed and mixed with RNA extraction reagent (this sample is referred to as “flow-through serum”). RNA was then extracted from the 3 samples using the method described in Example 2, and the RNA from each sample was resuspended in an equal volume (30 μL) of 0.1 mM EDTA. Equal volumes of RNA recovered from each sample was used for detection of a microRNA, miR-191, as described in Example 3. The Ct values are shown below.
[0000]
Prefiltration serum
Serum filter
Flow-through serum
Avg Ct miR-191:
Avg Ct miR-191:
Avg Ct miR-191:
32.31
27.83
34.01
[0036] The ability of the filter to concentrate RNA signal from human serum is verified by comparing the mir-191 signal in RNA extracted from unfractionated serum and in the flow-through sample, with the level in RNA extracted from purified MPs. The signal in the filter sample is approximately 22-fold greater than in the prefiltered sample (2̂4.48) and 73-fold greater than in the flow-through sample (2̂6.18). The flow-through sample is depleted from miR-191 signal by ˜3.2 fold compared to the prefiltration sample (2̂1.7).
[0037] In the experiments described above, filters with captured MPs were processed by flushing them with RNA extraction reagent, which immediately disrupts the MN and stabilizes their RNA. While this procedure will be useful for serum biomarker discovery, for use as delivery vehicles, the MPs would need to be recovered as intact particles. A further embodiment is to recover intact MPs after their entrapment on filters. To recover intact MPs, the filters with MPs could be removed to vessels containing a physiological buffer such as PBS and vortexed to release the MPs, or the filters with trapped MPs could be back-flushed with a physiological buffer such as PBS to release the intact trapped particles.
Example 5
Analysis of RNA from Conditioned Media on Agilent Bioanalyzer
[0038] RNA was extracted as described in Example 2, from MPs trapped on filters from conditioned media and from the corresponding flow-through, and analyzed on an Agilent Bioanalyzer as shown in FIG. 1 . This instrument uses capillary electrophoresis to separate RNA samples according to size. In the electropherograms shown below, the concentration of RNA in the samples is reflected by the height of the peaks (the higher concentration, the higher the peak height) and the size of the RNA is reflected in the position of the peak along the X-axis (the larger the RNA, the further it migrates in the right-hand direction). The small “hump” seen in the lower left-hand corner of the electropherogram traces in Samples 7, 8, 9, and 10 in the FIG. 2 is the RNA recovered from MPs trapped on 20 nanometer filters from 4 different conditioned media samples. Samples 11, 12, 13, and 14 show material extracted from the corresponding flow-through conditioned media. The lack of the peak in Samples 11-14 indicate that the filters were highly effective for recovering RNA from the conditioned media samples. The position of the peak near the left-hand side of the X-axis, and the lack of peaks further to the right, shows that all of the RNA detectable by this instrument in RNA retained on the filters was small RNA, of a size range centered around ˜100 bases (as calibrated by comparison of the peak positions to the molecular size marker “ladder” shown in the last panel).
Example 6
Use of Biomolecules Recovered from MPs for Biomarker Discovery
[0039] It is contemplated that RNA recovered from fractionated MPs obtained from different samples of cell-free bodily fluids will be used as input for determination of the relative levels of multiple different microRNAs in the samples (a process known as “microRNA profiling”). Comparison of microRNA profiles between different types of samples will allow associations to be made between microRNA profiles and phenotypic differences between the samples. For example, microRNA profiles in RNA extracted from size-fractionated MPs obtained from cell-free bodily fluids from healthy individuals, can be compared with microRNA profiles in RNA extracted from size-fractionated MPs obtained from cell-free bodily fluids from individuals known or suspected of having pathological condition(s), and appropriate analyses carried out to identify differences in microRNA profiles that can be correlated with specific pathological condition(s). In a similar manner, it is contemplated that RNA recovered from fractionated MPs obtained from different samples of conditioned media derived from primary or long-term cultures of cells grown in vitro will be used as input for determination of the relative levels of multiple different microRNAs in the samples. Comparison of microRNA profiles between different types of conditioned media samples will allow associations to be made between the microRNA profiles and phenotypic differences of the individuals from whom the cells that were used to generate the conditioned media were obtained. For example, microRNA profiles in RNA extracted from size-fractionated MPs obtained from conditioned media recovered from cells cultured from healthy individuals, can be compared with microRNA profiles in RNA extracted from size-fractionated MPs obtained from conditioned media recovered from cells cultured from individuals known or suspected of having pathological conditions, and appropriate analyses carried out to identify differences in microRNA profiles that can be correlated with specific pathological conditions.
[0040] In a similar manner, it is further contemplated that proteins and other types of nucleic acid, including DNA and messenger RNA (mRNA) recovered from fractionated MPs obtained from different samples of cell-free bodily fluids and conditioned media will be used as input for determination of the relative levels of multiple different proteins and other types of nucleic acids. Comparison of levels of proteins and other types of nucleic acids between different types of samples will allow associations to be made between their levels and phenotypic differences between the samples. For example, levels of proteins and/or mRNA extracted from size-fractionated MPs obtained from cell-free bodily fluids from healthy individuals or from conditioned media derived from the cultured cells of healthy individuals, can be compared with levels of proteins and/or mRNA extracted from size-fractionated MPs obtained from cell-free bodily fluids or conditioned media derived from the cultured cells of individuals known or suspected of having a pathological condition, and appropriate analyses carried out to identify differences in microRNA profiles that can be correlated with specific pathological condition(s). In all of the above examples, it is contemplated that observed differences in levels of analytes between samples can be validated for use as biomarkers.
[0041] Further modifications and alternative embodiments of various aspects of the invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the general manner of carrying out the invention. It is to be understood that the forms of the invention shown and described herein are to be taken as examples of embodiments. Elements and materials may be substituted for those illustrated and described herein, parts and processes may in some cases be reversed, and certain features of the invention may be utilized independently, all as would be apparent to one skilled in the art after having the benefit of this description of the invention. Changes may be made in the elements described herein without departing from the spirit and scope of the invention as described in the following claims. | Described herein are methods, devices, and compositions for fractionation and processing of microparticles from biological samples, and to methods for obtaining and using the microparticles for biomarker discovery. Biological samples include cell-free fluids, for example blood plasma, blood serum, cerebrospinal fluid, urine, and saliva, as well as conditioned media. Conditioned media is the liquid growth media used to propagate cells in vitro. Purification of microparticles from cell-free fluids is challenging, typically accomplished by prolonged ultracentrifugation. Described herein is an alternative method for efficiently harvesting and processing microparticles from cell-free fluids and from conditioned media. Embodiments described herein relate to use of the microparticles and their contents recovered from conditioned media derived from propagation of human and animal cells, as a source of biomarkers for diagnosis and prognosis of diseases and pathological conditions. | 48,250 |
RELATED APPLICATIONS
[0001] Applicant has no other prior or copending U.S. Patent applications, including any provisional or non-provisional utility or design patent application, or any prior foreign or internationally filed applications on the invention, and makes no claim for any domestic or foreign priority in this application.
STATEMENT OF GOVERNMENT INTEREST
[0002] There is no property interest of the government in any aspect of this invention. This invention was not made while the applicant was either under the employment of any government agency, or under any contract or grant from any government agency.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to promoting the visibility of eyeglasses and an optional buoyancy means to keep eyeglasses afloat and visible allowing their retrieval in the event the eyeglasses are either dislodged from the wearer or are accidentally dropped into the water.
[0005] The proposed primary classification for this invention is class 351, Optics, subclass 43, floating spectacles or eyeglasses.
[0006] 2. State of the Prior Art
[0007] The prior art shows discloses various methods to alter the appearance of the temple pieces of eyeglasses but none shows separate elastomeric sheaths on each temple piece, that are not attached to each other, for promoting visibility of the eyeglasses. The prior art discloses various types of retainers or floats for eyeglasses. Methods have been shown to attach a floatation member to eyeglasses via a retainer which can be looped around the neck, arm or leg of the wearer. Other methods show customized frames which have float pads specifically made to fit these frames as a means of buoyancy. These floats are either bonded directly to the frames or are snapped into cutouts in the frames. Still other methods show elastomeric bands or loops attached to a floatation device through which the temple piece of the eyewear is fed in an attempt to secure the device to the temple piece. These bands or loops are permanently attached to the member and because they are of a predetermined size, they cannot effectively adapt to a variety sizes or shapes of different temple pieces. Yet another method incorporates a floatation member with internal slits that surround the temple portion of the frame and are held in place by elastomeric bands or alternatively by a conventional hook and loop means such as Velcro®. In this case, the slits can be widened to accommodate a thick temple piece however, once this is performed, it is irreversible. The prior art additionally discloses a floatation device wherein a longitudinal passage accommodates a temple piece, but the passage is such that a substantially major portion of the float member must be disposed on the lateral side of wearer's temple piece. None of the prior art provides a removable and reusable device that promotes upward tipping of the eyeglass temple pieces when floating in the water, or a removable and reusable device that can be easily adapted to securely fit temple pieces of various shapes and sizes. Also, none of the prior art teaches a customizable, easily reversible method of adding weight to the buoyancy means to alter the center of gravity of the spectacles, which in turn affects the visibility of the buoyancy means above the water's surface. The prior art shows a method to adhesively stack additional buoyancy members to a floatation device however it does not teach the reversible method of adding additional buoyancy members at a desired position along the floatation device. Furthermore, none of the prior art gives the end user a method to create enhanced visibility by the selective placement of the buoyancy member at various positions on the temple piece and/or selectively and reversibly adding buoyancy material and/or weight at a desired position along the buoyancy means. Additionally, the prior art does not teach how the shape of the buoyancy means influences the floatation properties of the combination of the buoyancy means on a pair of glasses in the water. The prior art shows a method to attach identification information to a pair of eyeglasses via a sleeve which is attached to the temple piece of the eyeglasses however, once this is done, the identification information cannot be easily removed or transferred to another pair of eyeglasses. Also in its preferred embodiment, it requires an intermediary recovery company to put the finder of the lost eyeglasses in touch with the owner of the eyeglasses.
SUMMARY OF THE INVENTION
[0008] The invention promotes the visibility of eyeglasses either on land or in water. An exemplary embodiment of the invention promotes visibility in lit and/or dark conditions by providing colorization and/or reflectivity and/or luminescence. A sheath means of the invention can be utilized to incorporate these visibility features. The invention may additionally include the application of the buoyancy means to the temple pieces of a conventional pair or eyeglasses. If the eyeglasses fall into water, the buoyancy means provides visibility by preventing the eyeglasses from sinking below the surface of water into which they have fallen and can be readily attached to and removed from a conventional pair of eyeglasses. The buoyancy means comprises various means to facilitate upward tipping of the end of the eyeglass temple pieces remote from the lens frame portion of the eyeglasses, hereafter referred to as distal, when floating in the water. In many embodiments, the buoyancy means can be used in combination with the optional placement of a temple sheath disposed over at least the distal end of the temple pieces to increase visibility when floating in water and improve the visibility of the temple pieces on either land or water.
[0009] The buoyancy means comprises one or more buoyancy members made of a material with a specific gravity less than one and of a volume and density sufficient to effect floatation of the combination of the buoyancy means and the eyeglasses. The specific gravity and/or the volume of the buoyancy member may vary along its longitudinal direction and affect the floatation and/or visibility of the eyeglasses. The buoyancy means includes the attachment means for removably and selectively securing the buoyancy means to the eyeglasses at various positions along the temple piece. An exemplary embodiment incorporates a resisting means to resist movement of the buoyancy means on the temple piece.
[0010] An exemplary embodiment of the invention has the ability to adapt to and securely fit a variety of temple sizes and shapes and can be used interchangeably from one pair of frames to the next without the need to permanently alter the eyeglasses or the invention. The buoyancy member can be segmented or one piece and can completely surround the circumference of the temple piece, surround a part of it, or be completely external to it. Sheaths and/or mating means such as hook and loop members like Velcro® can be used as part of the attachment means to secure the buoyancy member to the temple piece. The sheath means can also be used to enhance the visibility and the comfort of the buoyancy means and to provide a means to add a weight member or an additional buoyancy member to it. An exemplary embodiment of the buoyancy means employs the use of a retainer means to provide a customizable, easily reversible system to add the weight member and/or the additional buoyancy member to a desired position along the buoyancy means which allows the buoyancy means to accommodate a wide variety of eyeglasses, each having a unique center of gravity, and to produce a tipping effect of the eyeglasses for improved visibility as they float. Another exemplary embodiment of the buoyancy means positions a greater volume of the buoyancy member inferior to the temple piece to promote desirable floatation properties and to enhance its visual appearance. Another exemplary embodiment of the buoyancy means places a greater volume of the buoyancy member towards the distal of the buoyancy means which also promotes desirable floatation properties. Furthermore, an exemplary embodiment of the buoyancy means has a means to personalize it with the user's contact information in the event the floating eyeglasses are lost and found by another individual. Also this identification information can be easily removed, transferred to a different pair of eyeglasses, if so desired, or can be easily amended or updated by simply attaching new contact information to the buoyancy means. This is an extremely efficient and inexpensive method to attach identification to the buoyancy means.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 shows a conventional pair of eyeglasses, wherein the temple pieces have a first end attached approximating the lens frame end of the eyeglasses, hereafter referred to as the proximal end or the lens frame end, and a second end approximating the earpiece end of the temple portion of the eyeglasses, hereafter referred to as the distal end.
[0012] FIG. 2 shows a temple piece of the eyeglasses of FIG. 1 , with a temple sheath applied over the temple piece to enhance the visibility of the temple piece. FIG. 2A shows a cross-sectional view of the temple piece and the temple sheath of FIG. 2 . The temple sheath may be employed over the temple piece in any embodiment of the invention.
[0013] FIGS. 2B , 3 , and 3 A show the buoyancy member applied to a temple piece of FIG. 2 to provide floatation of the eyeglasses. FIG. 2C demonstrates a tipping angle (a) relative to the surface of the water (w). FIG. 3 is a cross-sectional view of the embodiment of FIG. 2B . FIG. 3A shows a modification of the embodiment of FIG. 3 demonstrating a variable volume along the buoyancy member's longitudinal length.
[0014] FIG. 3B provides a cross-sectional view of FIG. 3 , and FIGS. 3C-3I show cross sections of various embodiments of the buoyancy member to promote stability of the buoyancy member from rotation over the temple piece, durability of the buoyancy member, and comfort for the wearer.
[0015] FIG. 4 shows the application of an external float sheath surrounding the buoyancy member and the optional retention of the weight member or the additional buoyancy member to it. FIGS. 4 , 4 A- 4 G show various means for promoting upward projection of the temple pieces and downward projection of the lens frame portion when floating in the water.
[0016] FIG. 4B shows the additional application of a resisting member, such as a conventional O-ring, to resist axial movement of the buoyancy member towards the distal end of the eyeglass temple piece. Also shown are a flap means which may be used to secure the additional buoyancy member and/or the weight member anywhere along the length of the flaps. These flaps are attached to the external float sheath. In FIG. 4C , the flaps are part of the external float sheath which are further clarified by the cross sections shown in FIGS. 4D and 4E . FIGS. 4F and 4G show how the flaps are folded to secure the additional buoyancy member and/or the weight member.
[0017] FIG. 5 shows a cross-sectional view of the external float sheath surrounding the buoyancy member.
[0018] FIGS. 6 and 7 show a unitary sheath which combines the temple sheath and the external float sheath into a single sheath. FIG. 7 also shows the addition of a tab attached to the distal end of the unitary sheath to facilitate the removal of the buoyancy means from the eyeglasses.
[0019] FIGS. 7A and 7B show a variation of the unitary sheath in which the flap means are attached to it and the distal end of the temple portion of the sheath is open ended and extends beyond the temple piece thereby not restricting the positioning of the buoyancy means towards the proximal end of the eyeglasses and additionally functioning like the tab in FIG. 7 by facilitating the removal of the buoyancy means from the eyeglasses.
[0020] FIGS. 8 and 9 show the additional use of a constricting means to provide additional radial pressure of the buoyancy member against the temple piece.
[0021] FIGS. 10 , 11 , 11 A, and 11 B show various embodiments for attaching the buoyancy member to the temple piece. FIGS. 10 , 11 , and 11 A show the use of an elastomer attached to the buoyancy member, and enclosing at least a portion of the temple piece. FIG. 11B shows the use of the external float sheath as a part of the attachment means.
[0022] FIGS. 11C and 11D show how the flap means can be used with this embodiment to secure the additional buoyancy member and/or the weight member. In FIG. 11C a single sheath is utilized to enclose part of the temple piece thereby forming a portion of the passage through which the temple piece passes, to function as the external sheath providing strength and visibility, and to form part of the flap means which can secure the additional buoyancy member and/or the weight member. In FIG. 11D the flap means are attached to the embodiment in FIG. 11B .
[0023] FIGS. 11E and 11F show alternate constructions of the buoyancy member to promote comfort against the temple region of the wearer, and to resist rotation of the buoyancy member when applied to the temple piece.
[0024] FIGS. 11G and 11H show means to resist longitudinal movement of the buoyancy member of FIG. 11B .
[0025] FIGS. 12-13I show the application of the attachment and retainer means surrounding the buoyancy member which dually functions as the attachment means to secure attachment of the buoyancy means to the temple piece at a specific position both vertically and longitudinally and as the retainer means to apply the weight member or the additional buoyancy member at a desired position along the attachment and retainer means. FIGS. 13F and 13I show a hook means to initially secure the buoyancy means to the temple piece by creating a purchase point to begin wrapping the attachment and retainer sheath around the temple piece and buoyancy member. FIG. 13G shows the use of the mating means to achieve similar results of the hook means of FIG. 13F . FIG. 13H shows the application of both the weight member and the additional buoyancy member to the buoyancy means.
[0026] FIG. 13J shows the application of the resisting means on the interior aspect of the buoyancy means that has a frictional surface which will contact the temple piece when applied to it and resist movement of the buoyancy means relative to the temple piece.
[0027] FIGS. 14-14B show the attachment and retainer means with multiple buoyancy members. As particularly shown in FIG. 14 , the use of an attachment and retainer sheath permits the buoyancy member to be formed as plural circumferential segments surrounding the temple piece, and secured by the attachment and retainer sheath.
[0028] FIGS. 15-16 show possible constructions of the plural buoyancy members of FIG. 14 .
[0029] FIGS. 17-21 show the buoyancy member attached proximate to, but not surrounding, the temple piece. Various means are shown to secure attachment of each buoyancy member proximate to an eyeglass temple piece.
DETAILED DESCRIPTION
[0030] With reference to the accompanying drawings, following is a detailed description of the various embodiments of the invention, and disclosure of how to make and use the invention.
[0031] As used herein, the term “eyeglasses” refers to any form of spectacles or eyeglasses, including commercial, over-the-counter glasses, prescription eyeglasses, clear-lens eyeglasses and sunglasses. The invention is not dependent upon the specific construction of the eyeglasses.
[0032] The term “mating means” refers to a connecting means comprised of a first mating member which engages a second mating member and provides reversible securement to each other. An example would be Velcro® which has a hook member which engages its mate, a loop member, to secure the two members together. Another example would be a snap which has a male and female member which engage each other when in function. When mating members are viewed in the drawings, unless otherwise described, it is to be understood that the mating members with different reference numerals in the same drawing are mates meant to engage each other. For instance, one numeral would represent the hook member and the other numeral would represent the loop member and that their engaging surfaces face each other when the buoyancy means is applied to the temple piece. For ease of viewing, one mate is single hatched and the other is cross hatched in the drawings. In the exemplary embodiments shown in the drawings, hook and loop members are shown and described as comprising the mating means but the mating means could be any conventional mating members.
[0033] The term “attachment means” refers to the means used to attach the buoyancy means to the temple piece. It could be a longitudinal passage formed entirely or partly by the buoyancy member, or it could be a longitudinal passage formed entirely or partly by the sheath, or it could be formed of a mating means with or without the use of an attachment sheath.
[0034] The term “retainer means” is a means to reversibly add the weight member and/or the additional buoyancy member to the buoyancy means. It can be comprised of the “flap means” in which flaps with mating members are used to secure the additional weight member and/or the additional buoyancy member. It can be made of the mating means or the mating means attached to the sheath means. In some embodiments, the attachment means can dually function as the retainer means in which it not only secures the buoyancy means to the temple piece but also provides a means to reversibly add the weight member and/or the additional buoyancy member to the buoyancy means. The retainer means could utilize other conventional means to secure additional weight members and/or buoyancy members such as pockets, pouches etc.
[0035] The term “buoyancy member” refers only to the portion of the buoyancy means with a specific gravity less than one which ultimately provides the buoyancy force necessary to overcome the weight of the combination of the buoyancy means and the eyeglasses and cause floatation of the combination when placed in water. The “buoyancy means” comprises at least one buoyancy member and the attachment means for attachment of the buoyancy means to the eyeglass temple piece and may optionally include retainer means.
[0036] The term “tipping angle” or “angle of stability” (a) as used herein refers to the angle formed between the surface of the water (horizontal in the drawings) and the final position of the temple piece once the tipping has occurred. The tipping angle can be varied to maximize the visibility of the combination.
[0037] The term “removable means” refers to any additional means that can be added to the buoyancy means that has a net specific gravity greater or less than one that will allow the user to affect the floatation and/or the tipping angle of the floating eyeglasses. The removable means could be a removable member itself or the removable member with a mating means attached to it to engage the mating means of the buoyancy means. A removable member that has a specific gravity less than one will be referred to here after as the “additional buoyancy member” or a “secondary buoyancy member” and a removable means that has a specific gravity greater than one will be referred to here after as a “weight member”.
[0038] The “sheath means” refers to the sheath portions of the buoyancy means which could be part of the attachment means and/or the retainer means and/or the flap means of the buoyancy means, could aid in connecting the various components of the buoyancy means into a unitary assembly, could aid in the removal of the buoyancy means from the temple piece, could aid in visibility properties including colorization, reflectivity and luminescence, could promote durability of the buoyancy means, and could promote comfort of the buoyancy means. The sheath means could be the sheath itself that incorporates colorization, and/or reflectivity and/or luminescence or the sheath and a member added to it to promote visibility such as colorization, and/or reflectivity and/or luminescence. The sheath means could be the temple sheath alone or any of the sheaths comprising the buoyancy means.
[0039] The term “center of buoyancy” as used herein refers to the point at which a single force vector could be placed to describe the buoyancy force on an object. The object could be the buoyancy member or means itself, or the combination of the buoyancy means and the eyeglass frames. In a stable position in the water, the center of buoyancy will be on a vertical line passing through the center of gravity so no net torquing forces are acting upon the object. If the object is in water at any other angle than the angle of stability, the center of buoyancy will have moved off the vertical axis passing through the center of gravity thereby creating torquing forces which will rotate the object and return it to the angle of stability.
[0040] The buoyant force acts on the object at the center of gravity of the displaced liquid. This will also be the center of volume of that portion of the object that is below the water, since the displaced water has a uniform density. This point is called the center of buoyancy. Floatation of the object will occur with the upper surface level of the object at the water line when the density of the object is the same as the liquid. If the density of the object is lower than that of the liquid, its net weight will be less than the buoyancy force, and a portion of the object will project above the water line. For the object to float stably, the center of gravity and the center of buoyancy must remain in a vertical line so that there is no net torque acting on the floating body causing it to rotate. In the equilibrium position of the floating object, the vertical line passing through the center of gravity is called the “centerline” of the object and is fixed with respect to the body.
[0041] In reality, the floating object will rarely come to rest at the tipping angle because in a pool, lake, ocean etc., there will almost always be some external forces acting upon the object such as ripples or waves in the water or wind. When these external forces act upon the floating object, the object is displaced from its state of equilibrium or stability and the center of buoyancy shifts off the center line, thus coupling forces are generated which produces a net torque which will try to right the object and return it to its state of equilibrium. Therefore, the floating object will almost always be swaying around its tipping angle. From a visibility standpoint, this movement can be advantageous in attracting the eye.
[0042] In each embodiment of the invention, a visibility means, which could be the sheath means and/or the buoyancy means, is applied to the temple piece of eyeglasses. In each embodiment of the buoyancy means disclosed herein, the buoyancy means extends longitudinally along or around a portion of the eyeglass temple piece. Upward tipping of the distal end of the eyeglass temple pieces is achieved in the various embodiments of the buoyancy means either by varying the longitudinal placement of the buoyancy means along the temple piece, by varying the density and/or volume of the buoyancy member along its longitudinal direction, or by applying additional weight to the buoyancy means near its proximal end.
[0043] Each drawing figure that shows a cross section of the temple piece and/or buoyancy member of the invention is oriented such that the temple region of the wearer will be to the right-hand side of the drawing. The buoyancy member or buoyancy members of the buoyancy means are formed of a material with an overall specific gravity less than one, such as a closed cell foam, and the buoyancy means contains sufficient volume of the buoyancy member or buoyancy members to overcome the weight of the combination of the buoyancy means, the eyeglasses and the optional temple sheath and cause floatation. A primary buoyancy member is permanently attached to the buoyancy means and the optional secondary buoyancy member can be reversibly added to the buoyancy means to achieve additional floatation. The primary and secondary buoyancy members can be made of the same material or different materials and can each have a varying density and/or volume along their length. Each embodiment hereafter can optionally contain a personalization means such as a trademark and/or logo and/or user information such as identification or contact information in the event that the floating eyeglasses are lost and then recovered by another individual. This could be in the form of a small piece of paper which is laminated to protect it from the water. It could be attached to the buoyancy means by any conventional means such as by bonding or by having a mating member bonded to its underside which will engage the mating member of the various embodiments of the buoyancy means. If the personalization means is attached to the buoyancy means via a mating member, then the personalization can be easily applied, removed, transferred, amended or updated. The personalization means could also be imprinted, embossed or otherwise incorporated by any conventional means to the sheath means or any visible internal and/or external part of the invention. The same customization applies for any information in general such as adding corporate logos or adding advertising information to the invention.
[0044] FIG. 1 is a depiction of a conventional pair of eyeglasses, having a pair of temple pieces 100 attached to a conventional lens frame portion 103 of the eyeglasses. For reference purposes in later description of the invention, each temple piece 100 of the eyeglasses has a “distal end” 101 or earpiece end, and a “proximal end” 102 attached to the lens frame 103 . The cross section of each temple piece may be freeform or may be of a conventional shape, including circular, ovular, or oblong, and may be of varied thickness, ranging from wire-rims to thickened members. The invention is applicable to most conventional eyeglass temple pieces.
[0045] FIG. 2 shows the application of a temple sheath 107 over at least the distal end 101 of each temple piece 100 . Temple sheath 107 is formed of a conventional resilient and flexible material. In a preferred embodiment this material is elastomeric, such as Spandex®, Lycra®, Latex®, or Nitrile®, that snuggly conforms to the temple piece 100 and allows for its reuse and its easy application and removal from the temple piece. In a preferred embodiment, if the elastomeric material is a woven fiber such as Spandex® or Lycra®, the seam is positioned at the distal end of the sheath, as in a sock or stocking, and does not span the longitudinal length of the sheath. In an exemplary embodiment, temple sheath 107 is durable, thin and brightly colorized, at least at the distal end 101 thereof, to promote visibility of the eyeglasses both when employed alone or when used with the buoyancy member, as shown in subsequent drawing figures. Although it is shown in many of the drawings, temple sheath 107 is optionally used by the wearer and is not mandatory to wear for the buoyancy means to function. In all embodiments, a temple sheath could be placed on the temple piece. It can cover just the distal end of the temple piece or can extend the entire length of the temple piece. FIG. 2A shows a cross-sectional view along section line 2 A of FIG. 2 . In an exemplary embodiment of the temple sheath, its proximal end has a raised rim of material, a gathered amount of material or an attached flexible structure 107 A, such as an O-ring, similar to a prophylactic or finger cot, so that the sheath can be rolled out as it is applied to the temple piece and rolled back as it is removed. In an exemplary embodiment, the sheaths could come in a variety of colors giving the user the flexibility of changing the appearance of the temple piece if so desired. In another exemplary embodiment of the temple sheath, reflectivity is applied to the surface of the sheath or is applied by attaching a reflective means to the temple sheath, by any conventional means such as bonding, which would reflect light at night. This could offer protection to a walker, jogger, runner or biker at night from a lateral light source. It could also provide nighttime visibility if the floatable eyeglasses are dropped in the water and a light source such as a flashlight is shone upon it. In another exemplary embodiment of the temple sheath, luminescence is applied to the surface of the sheath or is applied to the sheath by attaching a luminescent means to it by any conventional means. The temple sheath could also be worn without the floatation device for visibility and/or aesthetic reasons.
[0046] FIG. 2B shows the application of the buoyancy member 104 over the temple piece 100 and temple sheath 107 . For reference purposes, relative to how each buoyancy means or member will be positioned on the temple piece, the buoyancy means or member has a “proximal” end towards the lens frame end of the eyeglasses, a “distal” end towards the earpiece end of the eyeglasses, a “superior” and “inferior aspect, and a “medial” and “lateral” aspect so the invention can be described using these 3-dimensional terms. For purposes of comfort to the wearer, the distal end of the buoyancy member is positioned at a longitudinal point just in front of the ear of the wearer. Also placing the buoyancy member as far distally as possible while still being in front of the ear promotes a greater tipping angle and improved visibility in water.
[0047] FIG. 2C demonstrates the tipping angle (α) of the floating eyeglasses relative to the surface of the water at the equilibrium position. In various embodiments of the buoyancy means, the ability to customize the tipping angle to promote maximum visibility is emphasized.
[0048] In embodiments having a longitudinal passage, the attachment means is the longitudinal passage. The constrictivity of the material or materials forming the longitudinal passage affect the retention of the buoyancy means to the temple piece.
[0049] FIG. 3 shows a cross-sectional view of the buoyancy member 104 , temple piece 100 , and temple sheath 107 of FIG. 2B , and depicts positioning the distal end of the buoyancy member in front of the ear 106 of the wearer. Buoyancy member 104 , and modifications thereof in subsequent embodiments, is formed of any conventional material having a specific gravity less than one, such as foam. In a preferred embodiment the buoyancy material is a closed cell low-density foam. Buoyancy member 104 surrounds the temple piece and has a longitudinal passage therein through which temple piece 100 and temple sheath 107 extend. The buoyancy member of any of the embodiments of the buoyancy means may be of any shape in cross section, including ovular, triangular, oblong or freeform. The longitudinal passage within the buoyancy member 104 is preferably of a cross-sectional shape and dimension congruent with and equal or slightly smaller than that of the temple piece upon which it is to be applied, thus forming a snug fit around the temple piece. Buoyancy member 104 is also preferably brightly colorized, at least towards the distal end 101 of each temple piece, to promote its visibility when floating in water. FIG. 3A , is a cross-sectional view of a modification of FIG. 3 which demonstrates that the buoyancy member need not have uniform volume along its length and can be of any shape. Furthermore, the buoyancy member and/or the buoyancy means can have varying densities along its length.
[0050] FIG. 3B is a cross-sectional view along section line 3 B of FIG. 3 , showing the temple piece 100 and temple sheath 107 extending through the longitudinal passage within the buoyancy member. FIGS. 3C-3H show various modifications of FIG. 3B to accommodate various considerations, as discussed in detail below. In each of FIGS. 3B-3H , the temple region of the wearer is to the right-hand side of the drawings. Points t 1 -t 4 shown in FIGS. 3B-3H for references purposes fall on a line extending on a horizontal plane through the vertical midpoint of the temple piece and through the innermost and outmost points of the buoyancy member. Points t 3 and t 4 show the intersection of that line with surface of the longitudinal passage within the buoyancy member.
[0051] Construction of the buoyancy means represents consideration of several factors, including the necessary volume of the buoyancy member to produce the required floatation, durability for reuse thereof, visibility, comfort of the wearer, and rotational stability of the buoyancy means over the temple piece. To these ends, various modifications of the buoyancy member are shown in FIGS. 3B-3H . While each of FIGS. 3B-3H show an essentially ovular temple piece and buoyancy member for illustrative purposes, the buoyancy member may take any desired shape, including circular, oblong, rectangular, triangular, or freeform. Similarly, the longitudinal passage within the buoyancy member, while depicted as generally ovular, may have a cross-sectional shape congruent to that of the temple piece upon which the buoyancy member is to be applied. FIGS. 3B and 3C show embodiments where the medial distance t 1 -t 3 and lateral distance t 2 -t 4 are substantially equal, thus providing substantially equal portions of buoyancy material on each side of the temple piece to promote durability thereof over repeated use. FIGS. 3D-3H each show the distance t 1 -t 3 being less than the distance t 2 -t 4 , thus providing less buoyancy material between the temple region of the wearer and the temple piece for improved comfort to the wearer. FIGS. 3E-3I show a planar surface on the inside of the buoyancy member proximate to the temple region of the user, promoting rotational stability of the buoyancy member over the temple piece during use. FIG. 3I shows a modification of FIG. 3F wherein the distance t 1 -t 3 may be at least equal to or greater than the distance t 2 -t 4 , thus increasing the amount of buoyancy material in the region between the temple piece and temple of the wearer, and providing increased durability of that portion of the buoyancy member subject to the most wear during use, while retaining rotational stability and comfort to the wearer by means of the planar inner surface of the buoyancy member. FIGS. 3 C and 3 F- 3 I show elongation of the buoyancy member in the vertical direction to provide an increase in overall volume of buoyancy material. FIGS. 3G and 3H show the longitudinal passage offset from the member's horizontal and vertical centerline of volume. FIG. 3G shows a major portion of the buoyancy member below or inferior to the temple piece, and reduced volume above or superior to the temple piece FIG. 3H shows a major portion of the buoyancy member above the temple piece and reduced volume below the temple piece The specific construction of the buoyancy member can thus be manufactured to meet the specific needs of a wearer.
[0052] An exemplary embodiment also takes into account the importance of the shape of the buoyancy means. Specifically, the construction of the buoyancy means with a greater volume of its buoyancy member towards its distal end promotes an increased tipping angle and better visibility. Also placement of a greater volume of the buoyancy material inferior to the temple piece further enhances this phenomenon. Furthermore, the cross-sectional shape of the buoyancy member can vary from the distal end to the proximal end of the member. Near the distal end where the member will approximate the face of the wearer, a soft, comfortable member with a minimal volume of buoyancy material medially between the temple piece and the user's face is desirable. However, moving proximally along the buoyancy means in the area where the temple piece of the wearer starts to separate from the face, it is less critical to have an offset passage in the medial-lateral aspect however it may be advantageous to have the passage offset in a superior-inferior aspect as shown in FIGS. 3G and 3H . The construction places the bulk of the of buoyancy material away from the user's face occupying a greater vertical component than horizontal which produces a more streamlined appearance. Also having a minor portion of the buoyancy member medial to the temple piece along its entire length may produce a structural weakness with repeated use or by trying to place this on a temple piece which has a large cross-sectional circumference relative to the cross-sectional circumference of the longitudinal passage. In this case, the buoyancy member may perforate or rip through on its minor medial side proximate to its longitudinal passage.
[0053] This presents the manufacturer with a dilemma. A higher density, less floatable, more durable foam may be used which resists this potential weakness but comfort may be sacrificed. If a low density, more floatable, less durable foam is chosen, structural integrity is increased at the expense of a potentially less comfortable floatation device. A compromise regarding this manufacturing dilemma may be reached by not offsetting the longitudinal passage its entire length in a medial-lateral direction and/or using a different density of buoyancy material along a portion of the buoyancy member's length. These principles can be applied to any embodiment with a longitudinal passage. Also surrounding the buoyancy member with a sheath offers structural support for the longitudinal passage.
[0054] An exemplary aspect of all embodiments of the buoyancy means is to promote floatation of the eyeglasses with the distal end 101 of the temple piece projecting upwardly above the water's surface, and the lens frame portion 103 projecting downwardly below the water's surface. The bright colorization of the temple sheath 107 and/or the buoyancy member 104 promotes visibility of the eyeglasses when floating in water. The tipping of the eyeglasses to promote the desired upward projection of the temple pieces when floating in water may be accomplished by any of the embodiments previously disclosed.
[0055] A float sheath 108 shown in each of FIGS. 4 , 4 A, 4 B, and 5 is formed of a conventional resilient material. In a preferred embodiment the resilient material is an elastomeric material such as Spandex®. The float sheath surrounds and is attached to the buoyancy member 104 by any conventional means such as by bonding or stitching. In an exemplary embodiment, the adhesive used as the bonding agent, which connects various components of the invention, retains its properties in the presence of water and/or salt water and is flexible, such as any conventional elastomeric adhesive, allowing the structures which it is connecting to retain their flexibility. Float sheath 108 can extend the entire length of the buoyancy member as shown in FIG. 5 , or a portion of it as shown in FIG. 4 , can be brightly colorized, and can additionally provide a means to retain the removable means 116 to the combination. The removable means could be the secondary buoyancy member 116 1 or the weight member 116 2 . The float sheath and all sheaths described hereafter and/or the buoyancy members can also have a reflective and/or luminescent surface to allow nighttime visibility as described previously with the temple sheath or can have a reflective or luminescent member attached to it to accomplish the same nighttime visibility. FIG. 4A shows mating member 116 A attached to float sheath 108 by any conventional means such as bonding or stitching. Mating member 116 B engages the mating member 116 A. Bonded to the non-engaging surface of mating member 116 B is removable means 116 which is either the weight member 116 2 or the secondary buoyancy member 116 1 . In a preferred embodiment, mating members 116 A and 116 B are hook/loop members. The removable means can come in various volumes, densities or weights giving the user flexibility in improving the tipping angle and visibility and/or floatation of the floating eyeglasses.
[0056] FIG. 4B is a modification of prior embodiments of the buoyancy means, with the application of the resisting means 115 around the temple piece 100 and temple sheath 107 and abutting the buoyancy member 104 to resist longitudinal movement of the buoyancy means towards the distal end 101 . Although shown abutting the distal end of the buoyancy means, the resisting means could also be placed abutting the proximal end of the buoyancy means to resist proximal movement. Resisting means 115 can be comprised of a removable resisting means, such as a conventional O-ring, which can be readily applied and removed. Resisting means 115 may be used with any embodiment of the buoyancy means disclosed herein. Additionally, FIG. 4B shows the flap means in which retainer flap sheaths 118 and 119 are formed of a conventional elastomeric material, such as Spandex®, and attached to float sheath 108 by any conventional means such as stitching. Attached by conventional means, such as bonding or stitching, to each flap on opposite sides are mating members 121 and 122 which are used to secure the flaps to each other when folded together. Alternately, mating members 121 and 122 can be attached directly to the float sheath 108 by conventional means such as bonding or stitching. The retainer means are then used to easily attach and then remove the removable means 116 to the buoyancy means anywhere along the length of the flaps. Shown for demonstration purposes in FIG. 4B is the secondary buoyancy member 1161 extending almost the longitudinal entire length of the retainer mating flaps. In an exemplary embodiment, the retainer means extends along most of the longitudinal length of the buoyancy member which gives the user the greatest flexibility in positioning the removable means. In an exemplary embodiment, the removable means has a mating member attached to one side as shown in FIG. 4A or opposite mating members attached to opposite sides as shown in FIG. 13C . The mating means of the removable means allow its easy attachment to the mating means of the buoyancy means so the user does not have to try to hold the removable member in place as he wraps the retainer means around it. Also, when the retainer mating means of the buoyancy means are disengaged, the mated removable means does not simply fall out and risk its potential loss. Additionally, the mated removable means can be secured at a specific position both vertically and longitudinally within the retainer means of the buoyancy means and thereby less subject to movement within the retainer means. Movement of the removable means within the retainer means of the buoyancy means could potentially change the tipping angle. Via the retainer means, the user has the ability to add buoyancy material to the buoyancy means, if needed, and also create the tipping angle of his choosing for increased visibility. A small amount and/or volume of weight can be added via the retainer means near their proximal ends which could dramatically affect the tipping angle and improve the visibility of the floating eyeglasses. The secondary buoyancy member can extend the entire length of the flaps as depicted in FIG. 4B , can be of any size which fits between the flaps and can be positioned anywhere along the length of the flaps. Also the material comprising the secondary buoyancy member can be different than the material comprising the primary buoyancy member of the buoyancy means. Since the secondary buoyancy member is not next to the user's face and is not stressed by taking the buoyancy means on and off of the eyeglasses, comfort and durability are not necessary criteria for it. Any buoyant material with a specific gravity less than one, such as bubble pack material or foam, could be used to form the secondary buoyancy member. The positioning of the secondary buoyancy member towards the distal end of the flap means also affects the tipping angle and increases visibility. Via these retainer means and the ability to add the weight member and/or the secondary buoyancy member at a desired position within the retainer means, the user could create a desired floatation effect on a pair of eyeglasses and then place the buoyancy means on a different pair of glasses with a different center of gravity and, through the same method, produce a similar floatation effect on the new pair of eyeglasses. The embodiments shown in FIGS. 4-4G , FIGS. 7-7A , FIGS. 11C-11D , FIG. 12-12C , FIGS. 13-13I , FIGS. 14-14B and FIGS. 17-21 can all use their mating means to achieve the effects listed above.
[0057] FIG. 4C is a variation of the embodiment shown in FIG. 4B in which the single retainer sheath 120 functions like the float sheath 108 and the retainer flap sheaths 118 and 119 of FIG. 4B . A cross section of FIG. 4B and FIG. 4C is shown in FIG. 4D and FIG. 4E respectively and the application of each to retain the removable means 116 is shown in FIGS. 4F and 4G . The single retainer sheath 120 could also be attached by any conventional means such as bonding or stitching to float sheath 108 shown in FIG. 4D which would be used in place of retainer flap sheaths 118 and 119 .
[0058] FIG. 5 shows a cross-sectional view of the external float sheath surrounding the buoyancy member. Float sheath 108 may be applied to any prior embodiment of the buoyancy means, and is preferably formed of a flexible elastomeric member, such as Spandex®. Float sheath 108 is preferably brightly colorized, at least towards the distal end 101 thereof, to further promote visibility of the eyeglasses when floating in water. Float sheath 108 extends over a substantial portion of buoyancy member 104 and may additionally extend to cover the entire member, or extend beyond the buoyancy member, and over the temple piece 100 towards the distal and/or proximal ends thereof.
[0059] FIG. 6 is a modification of FIG. 5 , and shows the unitary sheath 109 extending interior and exterior of the buoyancy member 104 , and performing the combined functions of the temple sheath 107 and float sheath 108 of FIG. 5 . Both ends 109 A and 109 B of unitary sheath 109 are preferably brightly colorized to promote visibility of the buoyancy means when floating in water.
[0060] FIG. 7 shows a modification of FIG. 6 wherein the unitary sheath 109 combines the temple sheath and the external float sheath into a single sheath which is bonded to the exterior surface of buoyancy member 104 , thus forming a single, unitary assembly. The entire assembly of sheath 109 and buoyancy member 104 of FIG. 7 may be inserted and removed as an integral assembly. Once applied over temple piece 100 , the tab member 111 , which is stitched or bonded to end 109 A of the sheath 109 or formed as an integral part of sheath 109 , may be grasped by the wearer to facilitate the removal of the unitary member 109 / 104 from the temple piece 100 . The tab also helps keep the distal end of the unitary sheath from passing into or thru the longitudinal passage when the buoyancy means is removed from the temple piece.
[0061] FIG. 7A shows a variation of the unitary sheath with an open end 109 C which has excess material extending past the distal end of the temple piece when positioned on the eyeglasses. This open end will not restrict the proximal placement of the buoyancy means on the temple piece and the excess material functions like the tab 111 of FIG. 7 to facilitate removal of the buoyancy means from the temple piece. The unitary sheath does not have to cover the entire external length of the buoyancy member. Additionally, retainer flap sheaths 118 and 119 have been attached to the unitary sheath by any conventional means such as stitching.
[0062] FIGS. 8 and 9 show the optional use of the longitudinal constricting means embedded within buoyancy member. As shown in FIG. 8 , constricting member 112 is embedded between portions 104 F and 104 G of buoyancy member. FIG. 9 provides a perspective view of the constricting member 112 , which is preferably formed as a braided member, commonly referred to as a “Chinese Finger Trap.” When disposed between buoyancy portions 104 F and 104 G, constricting member 112 resists longitudinal axial movement of the buoyancy member along the temple piece towards either the distal or proximal ends thereof. However, due to the flexibility of the buoyancy member and constricting member 112 , inward axial pressure from the ends of the buoyancy member will release the constricting pressure of member 112 , and permit removal of the buoyancy means from the temple piece.
[0063] FIGS. 10 , 11 , and 11 A-D show alternate embodiments of the buoyancy means where the buoyancy member has no component medial to the temple piece, with the longitudinal passage therein having a portion facing the temple of the wearer formed of a thin, soft elastomeric material for the purposes of improved comfort for the wearer and better accommodation of temple pieces of varying sizes. In FIGS. 11 and 11A , the portion of the buoyancy member proximate to the temple region of the wearer is replaced by an elastomeric member 113 or 114 , such as Spandex®, that is attached to the buoyancy member, such as by bonding. As shown in FIG. 11 , the elastomeric member 113 may be embedded within modified buoyancy member 104 H. As shown in FIG. 11A , the elastomeric member 114 is attached to the buoyancy member 104 I, thus forming a longitudinal passage within the buoyancy member. Elastomeric members 113 and 114 provide multiple functions. They decrease the bulk of the buoyancy means proximate to the wearer's temple region, they provide more comfort against the wearer's temple region, and the elastic nature of the material can better accommodate temple pieces of various sizes.
[0064] FIG. 11B shows use of the elastomeric float sheath 108 , as shown in FIGS. 3C , 3 D, 4 , and 5 , to form a passage for receiving the temple piece 100 . Elastomeric sheath 108 is attached, such as by bonding, to buoyancy member 104 J circumferentially counterclockwise from location 108 A to 108 B, as viewed in FIG. 11B . Elastomeric sheath 108 in not attached to buoyancy member 104 J in the circumferential portion extending clockwise from 108 A to 108 B, as viewed in FIG. 11B . Temple piece 100 is disposed in the longitudinal passage within the buoyancy member between buoyancy member 104 J and the unattached portion of elastomeric sheath 108 . FIG. 11C shows how this embodiment can use sheath 120 to function as part of the attachment means enclosing part of the temple piece and thereby forming a portion of the passage through which the temple piece passes, to function as the external sheath providing strength, durability and visibility, and to form part of the retainer means which can secure the secondary buoyancy member and/or the weight member. FIG. 11D shows the attachment, by any conventional means such as stitching, of the retainer means comprised of retainer flap sheaths 118 and 119 and mating members 121 and 122 to the float sheath 108 .
[0065] FIG. 11E shows buoyancy member 104 J, as applied in FIG. 11B . In a preferred embodiment, buoyancy member 104 J is formed of a flexible material, such as a conventional compressible low-density closed cell foam, that will deform when in contact with temple piece 100 , thus contouring at least in part to the temple piece. FIG. 11F shows a modification of FIG. 11C that may be employed when the buoyancy member is formed of a material with relatively low compressibility, such as Styrofoam®. To that end, FIG. 11F shows a modified buoyancy member 104 K having the contour to accommodate the temple piece formed therein. The contoured portion of buoyancy member 104 K may be produced during its formation, such as by conventional molding or casting, or may by machined into the buoyancy member 104 K after its formation. The contour may be of various sizes and shapes, depending upon the anticipated size and shape of the eyeglass temple pieces to which the buoyancy member is to be applied.
[0066] FIGS. 11G and 11H show the use of a longitudinal resisting means applied to the embodiment of FIG. 11B in the form of string members 115 A retained between float sheath 108 and buoyancy member 104 J just above and below points 108 A and 108 B. As shown in perspective view in FIG. 11G , the longitudinal resisters 115 A extend from each end of the buoyancy member, and may then be wrapped and/or tied around the temple piece to resist longitudinal movement of the buoyancy means. In an exemplary embodiment, the string members are formed of or are coated with a material that has increased frictional resistance to produce a low-slip surface, especially in the presence of water.
[0067] While there are some advantages to floatation means with a longitudinal passage, longitudinal slits or loops of a predetermined size in securing the means, there are many disadvantages. The ease of placement by trying to feed the temple piece through the passage can be cumbersome. The material creating the longitudinal passage is constantly stressed as the buoyancy means is applied and removed from the temple piece so it may break down over time. Many times a temple piece is not of uniform cross-sectional circumference along its length. For instance with a wire rim temple piece, the distal earpiece is considerably larger in circumference than the wire rim along the temple piece.
[0068] In this case, the passage has to expand to get past the larger distal earpiece and then contract and constrict around the wire rim and attempt to secure the floatation means to it. If the material surrounding the longitudinal passage is soft and flexible enough to get past the earpiece, it may not offer much constricting force or frictional resistance when it rebounds to the shape of the wire rim. Furthermore, since temple pieces come in such a wide range of circumferences, a buoyancy means that fits a wire rim snuggly may have a lot of difficulty fitting a temple piece on a different pair of eyeglasses with a huge circumference relative to the wire rim and may rip through or permanently alter the passage when the user attempts to feed the temple piece through the passage. Therefore, the longitudinal passage may restrict the ability of the user to use the buoyancy members interchangeably between different eyeglasses. The dilemma between selecting a durable buoyancy material and a flexible buoyancy material has been previously discussed. If the passage has a substantially minor portion on one side of it, this potential for rip through may be particularly relevant especially when the buoyancy member is structurally stressed by the constant application and removal of the buoyancy member and by waves stressing it in the ocean. Also in the longitudinal-passage floatation devices, there is a portion of the buoyancy material abutting the temple region of the wearer, so a soft, comfortable material is preferred. This may restrict the manufacturer from selecting a buoyancy material with more desirable floatation properties. Also a longitudinal passage may influence and restrict the overall shape of the buoyancy member. For instance, if the desired shape of the buoyancy member tapers to a point at one end, similar to the point of a cone, creating a longitudinal passage through a point is not possible. There has to be a sufficient volume of material through which a passage can pass. Also the resisting means later described as 115 B would be impractical to apply to the buoyancy means with a longitudinal passage. Furthermore, the longitudinal passage determines where the buoyancy member will be placed relative to the temple piece and is predefined by its construction. Additionally, a minor portion of the buoyancy member medial to the longitudinal passage implies that there will be some bulk or volume of the buoyancy member medial to the temple piece which can affect the overall comfort for the wearer and possibly stress the temple piece itself.
[0069] The following embodiments were designed to address these potential disadvantages of a buoyancy member with a longitudinal passage. The construction of a buoyancy means that wraps around a temple piece addresses fitting and securing the buoyancy means to a wide variety of shapes and sizes of temple pieces on different eyeglasses and also allows it to be used interchangeably between the different eyeglasses without permanently altering the buoyancy means. The wrap-around embodiments also address a temple piece that does not have a uniform circumference or shape along its length. The sheath means and mating means can be tailored to fit the buoyancy member of any shape. Since there is no longitudinal passage, the shape of the buoyancy member is much more flexible. The medial side of the attachment means can be made with only a sheath or a sheath and a mating member where the temple piece abuts the face of the user, which minimizes the thickness of the buoyancy means proximate to the face, thereby improving comfort while simultaneously having a very durable structure at the thinnest portion of the buoyancy means. This also places minimal stress on the temple piece itself because it is not forced laterally away from the face trying to accommodate the thickness of a longitudinal-passage buoyancy member. This is particularly relevant in an eyeglass frame in which the temple pieces fit snuggly against the face of the wearer. The wrap-around embodiments of the buoyancy means overcomes the potential weakness of the offset passage in the longitudinal-passage embodiments. Furthermore, the resisting means can be incorporated in the interior part of the wrap-around embodiments which resists axial, vertical and rotational movement of the buoyancy means relative to the temple piece. The selection of the potential buoyancy material and its density is broader since the wrap-around embodiments can be made with no portion of the member medial to the temple piece. Also the attachment and retainer means can dually function as both the attachment means to secure the buoyancy means to the temple piece and the retainer means to secure a removable member.
[0070] FIGS. 12-16 show embodiments wherein the buoyancy means has one or more buoyancy members 104 A and/or 104 C. The buoyancy members are retained to temple pieces 100 by means shown in FIGS. 13-13I and FIGS. 14-14B .
[0071] FIG. 12 shows a perspective view of the buoyancy means 105 applied over the temple piece 100 . FIGS. 12A , 12 B and 12 C show embodiments in which the mating members are on the same side of the attachment and retainer sheath. Details of the buoyancy means 105 are shown in FIGS. 13 and 13 A- 13 C. The bulge in the lateral aspect of the buoyancy means where cross section 13 B is taken demonstrates the selective placement of the removable means. It is easy to contemplate the ability to position the weight member and/or the secondary buoyancy member anywhere along the length of the attachment and retainer means between the mating members 105 B and 105 C. In this case, the attachment means dually functions as the retainer means. In a preferred embodiment, mating members 105 B and 105 C are hook/loop members such as Velcro®. To achieve the desired floatation effects, the user may elect to add the weight member to the proximal end and the secondary buoyancy member to the distal end of the buoyancy means.
[0072] FIG. 13 shows details of the buoyancy means 105 of FIG. 12 prior to its attachment to the temple piece 100 . Buoyancy means 105 comprises an elastomeric attachment and retainer sheath 105 A, such as Spandex®, with mating members 105 B and 105 C attached on opposite surfaces and ends of sheath 105 A by any conventional methods, such as sewing or bonding. Buoyancy means 105 additionally includes the buoyancy member 104 A, which is attached to the elastomeric attachment and retainer sheath 105 A on the same surface but opposite end as mating member 105 C. For purposes of discussion, the buoyancy member is attached to the inner surface of the attachment and retainer sheath and the opposite surface will be referred to as the outer surface.
[0073] FIG. 13A shows the buoyancy means 105 of FIG. 13 applied to eyeglass temple piece 100 . Mating members 105 B and 105 C contact each other to secure the attachment of the floatation means to the temple piece 100 .
[0074] FIG. 13B shows a modification of FIG. 13A , wherein the removable means is disposed between the mating members 105 B and 105 C. FIG. 13C shows details of the removable means. Member 116 has mating members 116 A and 116 B bonded to opposite surfaces thereof which engage the mating members 105 B and 105 C and can be applied anywhere along the length of the buoyancy means to achieve the desired floatation effects. Alternately, the additional buoyancy member or the weight member can be secured between members 105 B and 105 C without bonding the mating member directly to the removable member 116 . In this case, the attachment and retainer means dually functions the attachment means and as the retainer means.
[0075] FIG. 13D shows a modification of the embodiment shown in FIG. 13 in which the mating an additional mating member 105 B 1 is secured to the buoyancy member 104 A and mating member 105 C is extended to proximate buoyancy member 104 A. This accommodates temple pieces of various sizes, thicknesses and shapes and allows the buoyancy means to be placed at any desired position both vertically and longitudinally along the temple piece as shown in FIG. 13E and FIG. 13H .
[0076] FIGS. 13F and 13I show the hook means 105 D used to initially secure the buoyancy means to the temple piece by creating a purchase point to begin wrapping the attachment and retainer sheath around the temple piece and buoyancy member. The hook means helps to align the superior part of the buoyancy means with the superior part of the temple piece, provides frictional resistance for longitudinal stabilization of the buoyancy means and facilitates placement of the buoyancy means. The hook means 105 D is made of a material which has sufficient resiliency to allow it to conform to the temple piece and sufficient rigidity to permit it to secure initial attachment of the buoyancy means to the temple piece. An exemplary embodiment of the hook means incorporates a surface which has frictional resistance which resists longitudinal or rotational movement of the buoyancy means along the temple piece. Hook means 105 D can be secured to the buoyancy means by being embedded in the buoyancy member 104 A or could alternately be attached between any of the layers 105 B- 105 A, 105 A- 104 A or 104 A- 105 B 1 by any conventional method such as bonding. Hook means 105 D can be made of a rubber, synthetic rubber, plastic or wire coated with a material which protects the temple piece from being scratched and also offers frictional resistance. Hook means 105 D can be placed at multiple places along the buoyancy means such as its distal end, proximal end and any intermediate points there along or it can extend the entire length of the buoyancy means.
[0077] FIG. 13G shows an alternate way to initially secure the buoyancy means to the temple piece via the mating means. Mating member 105 B 2 , which is an extension of external mating member 105 B, extends beyond the attachment and retainer sheath 105 A and has mating member 105 C 1 attached to it by any conventional means, such as by bonding or stitching, in a manner in which the backing (non-mating) surface of 105 B 2 contacts the backing (non-mating) surface of 105 C 1 . This means that the mating surfaces of 105 B 2 and 105 C 1 face in opposite directions and are not engaged. Members 105 B 2 and 105 C 1 form a securing flap to initially secure the buoyancy means to the temple piece. When the securing flap is folded over the temple piece, mating member 105 C 1 engages internal mating member 105 B 1 inferior to the temple piece to initially secure the buoyancy means to the temple piece, then mating member 105 C is wrapped in the opposite direction and engages mating member 105 B 2 when the attachment and retainer sheath is folded around the temple piece and the buoyancy member and finally mating member 105 C engages the external mating member 105 B. As with the hook means, the securing flap can extend the entire longitudinal length of the buoyancy means or a portion of it and can be a single structure or can be plural securing flaps positioned at points along the length of the buoyancy means.
[0078] FIG. 13H shows a perspective view of the application of the buoyancy means shown in FIG. 13E to the temple piece. Also shown are hidden removable buoyancy member 116 1 and removable weight member 116 2 retained by the mating attachment and retainer means of the buoyancy means. In this embodiment and the following embodiments, the attachment and retainer means can dually function as both the attachment means and the retainer means. This drawing depicts that both removable members can be simultaneously added at any position along the length of the buoyancy means. In an exemplary embodiment, the removable means are positioned within the attachment and retainer means to maximize visibility of the floating eyeglasses.
[0079] FIG. 13J shows a perspective view of the interior aspect of FIG. 13D with the addition of resisting means 115 B. Resisting means 115 B is shown as angled strips in FIG. 13J but could run horizontally, vertically, grid shaped, curved or freeform along the interior of the buoyancy means in the zone where the temple piece is contemplated to be placed. Resisting means 115 B can be used in any embodiments in which the buoyancy means is wrapped around the temple piece such as those shown in FIGS. 13-13J , FIGS. 14-14B and FIGS. 17-21 . In FIG. 13G , the resisting means could be attached to the surface of 105 C 1 which contacts the temple piece. Resisting means 115 B can be attached to the mating members and/or sheaths and/or buoyancy members of the buoyancy means by any conventional method such as bonding or stitching. In an exemplary embodiment, their placement will ensure sufficient frictional resistance in the area that the temple piece is contemplated contacting the buoyancy means to resist axial, vertical and rotational movement of the buoyancy means. The resisting means has a highly frictional surface meant to contact the temple piece and offer resistance to movement in the longitudinal, and/or vertical and/or rotational directions. An exemplary embodiment has the resisting strips constructed of a material such as a rubber or a synthetic material which has a high coefficient of friction in the presence of water. The resisting means are attached to mating members 105 B 1 , 105 C 1 and 105 C by any conventional means such as bonding or stitching on where the temple piece will contact the interior of the buoyancy means. The mating members firmly press the resisting strips against the temple piece or the temple sheath surrounding the temple piece creating the frictional points of contact which will help resist the movement of the buoyancy means on the temple piece. In an exemplary embodiment, the positioning and thickness of the resisting means takes into account the creation of increased frictional resistance while allowing sufficient contact of the mating members to press the resisting means against the temple piece. Because axial positioning of the buoyancy means along the temple piece is a factor in creating a desirable tipping angle, this exemplary embodiment of the buoyancy means helps the buoyancy means remain where it is positioned on the temple piece when it is subjected to external forces such as waves in the ocean. Since the resisting means is on the interior surface of the buoyancy means, once the buoyancy means is applied to the temple piece, the resisting means is not apparent visually and does not detract from the cosmetic appearance of the buoyancy means.
[0080] FIG. 14 shows a modification of FIG. 12 , wherein the buoyancy means 117 , which contains plural buoyancy members 104 A and 104 C, is retained to the temple piece 100 .
[0081] FIGS. 14A and 14B show details of the buoyancy means 117 of FIG. 14 , which is similar in construction to floatation means 105 of FIG. 13 . Buoyancy members 104 A and 104 C are attached by any conventional means such as bonding to attachment and retainer sheath 105 A on the same surface as the mating member 105 C. FIG. 14B shows floatation means 117 applied to an eyeglass temple piece 100 in a manner similar to that of floatation means 105 of FIG. 13A . While FIGS. 14A and 14B show two buoyancy members 104 A and 104 C, any number of additional buoyancy members may be provided and similarly attached to member 105 A.
[0082] FIGS. 15 and 16 show a modification of the buoyancy members 104 A and 104 C of FIGS. 12-14 , wherein the buoyancy members 104 A and 104 C include contour portions 104 B and 104 D, respectively, contoured to conform to temple piece 100 , thus promoting a snug fit of the buoyancy members against the temple pieces. Contour portions 104 B and 104 D may be particularly desirable in the event the buoyancy members 104 A and 104 C are formed of a relatively incompressible material, such as Styrofoam®, which does not readily deform. Contours 104 B and 104 D may be created during formation of the buoyancy members, such as by conventional casing or molding thereof, or may be machined as cutouts after formation of the buoyancy members. FIG. 16 additionally shows a planar face on buoyancy member 104 C to reduce the bulk of the buoyancy member towards the user's temple region and to produce rotational stability.
[0083] FIGS. 17-21 show alternate embodiments of the buoyancy means, wherein the buoyancy member, in various embodiments, is secured external of the temple piece 100 . In each of FIGS. 17-21 , the removable means 116 of FIG. 13C may optionally be applied at the user's discretion between the mating members of the attachment and retainer means at a desired position to promote upward tipping of the distal end 101 of the temple pieces 100 , and downward tipping of lens frame portion 103 . FIG. 17 , FIG. 20 and FIG. 21 show an embodiment in which the buoyancy means can be attached at a desired vertical position relative to the temple piece by determining where the mating members are engaged below or above the temple piece. The buoyancy member shown in FIGS. 17-21 can be of any shape and can also have the resisting means 115 B attached to surfaces in which the temple piece (with or without temple sheath 107 ) is contemplated contacting the interior of the buoyancy means.
[0084] FIG. 17 shows the attachment of buoyancy member 104 L to temple piece 100 . Internal mating attachment and retainer member 200 , which in and exemplary embodiment is formed of a conventional hook and loop material, such as Velcro®, is attached to the buoyancy member 104 L by any conventional method, such as bonding. External mating attachment and retainer member 201 , in and exemplary embodiment is also comprised of a conventional hook and loop material, surrounds temple piece 100 and internal mating attachment and retainer member 200 . In a further modification of the buoyancy means, external member 201 may additionally be attached to internal mating attachment and retainer member 200 at point 208 by any conventional method, such as stitching. The elastomeric attachment and retainer sheath 203 , formed of a material such as Spandex®, may additionally be attached to mating attachment and retainer flap member 201 , and is preferably brightly colored to promote visibility of the buoyancy means when in the water.
[0085] FIG. 18 shows an optional means for securing the external mating attachment and retainer flap member 201 to the buoyancy member 104 L. In this embodiment, end 201 A of external mating attachment and retainer flap member 201 is embedded within the buoyancy member 104 M. Internal mating attachment and retainer member 200 may terminate above the temple piece 100 , as shown in FIGS. 18 and 19 , but may optionally extend below the temple piece 100 , as shown in FIG. 17 .
[0086] FIG. 19 shows an optional means of attachment of the external mating attachment and retainer flap member 201 to the buoyancy member 104 L. In this embodiment, the resilient float sheath 202 surrounds and is attached to the buoyancy member 104 L. Internal mating attachment and retainer member 200 is attached to sheath 202 . End 201 A of mating attachment and retainer flap member 201 is attached, such as by stitching or bonding, to float sheath 202 at point 204 . Internal mating attachment and retainer member 200 may terminate above the temple piece 100 , as shown in FIG. 19 , but may optionally extend below the temple piece 100 as shown in FIG. 17 .
[0087] FIGS. 20 and 21 show an alternate embodiment of the buoyancy means, wherein buoyancy means 205 is attached to each temple piece 100 . FIG. 20 shows buoyancy means 205 prior to attachment to temple piece 100 . Buoyancy means 205 comprises the sheath means 205 A of flexible elastomeric material with a mating attachment and retainer member 206 attached on one side and end of the sheath, and a mating attachment and retainer flap member 207 attached on the opposite side and end of the sheath. Sheath means 205 A is preferably brightly colorized. 205 B and 205 C identify opposite ends of the sheath 205 A for orientation purposes. Sheath means 205 A is attached to the buoyancy member 104 L, as shown in FIG. 20 .
[0088] FIG. 21 shows the buoyancy means 205 of FIG. 20 applied to an eyeglass temple piece 100 . Sheath means 205 A with attached mating attachment and retainer member 207 surrounds temple piece 100 and continues circumferentially around and over the buoyancy member 104 J, with mating attachment and retainer flap member 207 engaging mating attachment and retainer member 206 . As shown in FIG. 21 , end 205 B of sheath means 205 A extends below temple piece 100 , but may optionally terminate above the temple piece 100 in a manner similar to mating attachment and retainer member 200 shown in FIG. 18 . Additionally, end 205 C of sheath means 205 A is shown in FIG. 21 as terminating at a point below the buoyancy member, but may optionally extend circumferentially to a position proximate end 205 B. Extra rigidity may be obtained by attachment of mating attachment and retainer members 206 and 207 by any method, such as stitching, at point 209 below the temple piece. | The invention promotes visibility when applied to a conventional pair of eyeglasses on land or in water and in lit or dark conditions such as the incorporation of colorization, luminescence or reflectivity to the invention. The invention can additionally comprise removable buoyancy applied to the eyeglass temple pieces which causes floatation of the eyeglasses should they be dislodged from the wearer in water. The invention can be selectively attached to a desired position on the temple piece and additional weight or buoyancy can be selectively and removably added to it to increase its visibility. The invention can also provide for personalization. | 77,047 |
This is a divisional application of Ser. No. 08/505,336, filed as PCT/JP94/02199 Dec. 22, 1994.
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a security system for preventing audio equipment, automotive audio equipment in particular, from being stolen.
BACKGROUND ART
Audio equipment which is prone to theft, incorporates an anti-theft system which uses a secret identification code for prevention of theft. Such an anti-theft system requires the purchaser of the audio equipment to manually enter a specific identification code, which the purchaser will remember, by using, for example, numeric keys which are on the equipment. The entered identification code is compared with a code stored in the equipment, and if the entered code is correct, the equipment is activated.
Generally, in prior art security methods for automotive audio equipment, a user identification code of several digits is manually entered by various numeric keys on the front panel of the equipment, and if the identification code is correct, as a result of a comparison with a code stored in the equipment, the equipment is activated.
Consider a situation where audio equipment is stolen from a vehicle. The equipment is first removed from the first vehicle and is then installed for use in another car. That is, the equipment is once removed from a battery and connected to another battery. The condition of battery connection, that is, a change in the condition of battery connections of the two vehicles, is detected as a variation in power supply and when this condition is detected, the above security method prevents activation of the equipment and the equipment remains inactive until the correct identification code is manually entered. Therefore, if the equipment is stolen from the vehicle, the equipment cannot be operated by persons other than the user of the equipment who knows the secret identification code of the equipment. An indication or warning to the effect that such an anti-theft feature is incorporated in the audio equipment is visibly attached to the vehicle or the equipment so as to deter potential thieves. Such an indication or warning attached to the vehicle or the audio equipment, implying that it is futile to steal the equipment, discourages potential burglars that may be contemplating stealing the equipment, thus preventing the equipment from being stolen.
However, not all audio equipment is provided with a large number of numeric keys, and the fewer the number of numeric keys, the fewer the number of possible combinations that can be used to code an identification number, resulting in a lower security level. One way to avoid this would be to use keys other than numeric keys to create a secret identification code, but this would increase the complexity of operation. Furthermore, it is more difficult for the user to remember the identification code if non-numeric keys are used.
In view of the foregoing, a security system for audio equipment which uses a recording medium, such as a compact disc, as a key has been proposed as disclosed in Japanese Patent Application No. 2-333681 (Japanese Patent Unexamined Publication JPA 4-205965(1992)) in which a security method for audio equipment uses recorded voices on the recording medium. This security method for audio equipment is characterized in that the information recorded on the recording medium is compared with information stored in an internal memory of the audio equipment, and the audio equipment is activated depending on the result of the comparison. Since this method requires only that the audio equipment recognizes the recording medium that is to be used for releasing a security operation, it is easier for a user to remember the recording medium than a secret identification code. Furthermore, since an enormous number of recording media are available for use, its security level is very high.
However, when a recordable medium is used as the recording medium, there is a possibility that the information recorded on the recording medium may be rewritten and may no longer match the information stored in the audio equipment, thus making it impossible to release the security operation. For example, in an audio system that uses a photomagnetic disc called a mini disc which has recently come into widespread use, a rewritable disc may be used, and the above problem occurs in a security system for a playback apparatus or a playback/recording apparatus which uses such a mini disc.
It is accordingly an object of the present invention to provide a security system for audio equipment which allows users to easily release the security operation without compromising a security level, and which is prevented from being put in unlockable condition by careless handling.
SUMMARY OF THE INVENTION
The present invention provides a security system for audio equipment which prevents the audio equipment, which reproduces signals recorded on a recording medium, from being stolen. The audio equipment, while being in an inoperable condition, is changed into an operable condition when data recorded on a recording medium during a playback condition matches an identification data stored in a memory, the security system comprises a mode setting means for setting the mode of the security system to a storing mode that allows the identification data to be stored into the memory by a prescribed operation, identification medium setting means for storing specifying data which specifies data recorded in the recording medium as identification data in the memory in the storing mode, judging means for judging whether or not the specifying data of the recording medium put in the playback condition is rewritable, and storing inhibiting means for inhibiting the identification data from being stored in the memory by the identification medium setting means when the specifying data of the recording medium put in the playback condition by the judging means is rewritable.
Further the invention is characterized in that the security system further comprises display means for indicating that the recording medium is not suitable for setting the identification data, when the specifying data of the recording medium put in the playback condition is rewritable.
Further the invention is characterized in that the security system further comprises ejecting means for ejecting the recording medium from the audio equipment, when the specifying data of the recording medium put in playback condition is rewritable.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing the configuration of audio equipment according to one embodiment of the present invention;
FIG. 2 is a diagram showing the arrangement of the front of automotive audio equipment according to one embodiment of the present invention;
FIG. 3 is a flowchart illustrating a main routine of different modes of operation;
FIG. 4 is a flowchart illustrating the processing of an ID disc setting mode;
FIG. 5 is a flowchart illustrating the processing of an ID disc cancel mode;
FIG. 6 is a flowchart illustrating the processing of an inoperable condition release mode;
FIG. 7 is a flowchart illustrating the processing of a master input mode;
FIG. 8 is a diagram for explaining the recording format of a compact disc;
FIG. 9 is a diagram showing the configuration of audio equipment according to another embodiment of the present invention;
FIG. 10 is a diagram showing the arrangement of the front of automotive audio equipment according to another embodiment of the present invention;
FIG. 11 is a flowchart illustrating a main routine of different modes of operation;
FIG. 12 is a flowchart illustrating the processing of an ID disc setting mode;
FIG. 13 is a flowchart illustrating the processing of an ID disc cancel mode;
FIG. 14 is a flowchart illustrating the processing of an inoperable condition release mode;
FIG. 15 is a flowchart illustrating the processing of a master input mode; and
FIG. 16 is a diagram for explaining the recording format of a mini disc.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of the present invention will be described below with reference to drawings. In the embodiment described hereinafter, a digital audio disc player called a compact disc player is taken as an example, but it should be appreciated that the present invention is also applicable for other types of digital audio disc players such as a mini disc player, as well as digital audio tape players and the like.
Before proceeding to a detailed description of an embodiment of the present invention, the signal recording format of compact discs will be described briefly. FIG. 8 shows a diagram for explaining the recording format of a compact disc.
As shown in FIG. 8, the compact disc has a lead-in area 31, a data area 32, and a lead-out area 33. Data specific to the particular disc (the number of music programs, start positions of programs, playing times, etc.), called TOC (Table Of Contents) data, are recorded in the lead-in area 31.
In the security method of the present embodiment, the user selects a particular compact disc and the contents (TOC data) recorded in the lead-in area 31 of the disc are written into a memory such as, for example, a rewritable ROM (EEPROM) or the like, contained in the audio equipment. The TOC data of the inserted compact disc is compared with the contents of the memory, and when they match, the audio equipment is made operable. Writing to the ROM is performed by using a ROM writer which is built in the audio equipment. Thus, by performing a prescribed operation, the contents recorded in the lead-in area 31 of the inserted compact disc are written into the ROM contained in the audio equipment.
FIG. 1 shows a block diagram of audio equipment (a compact disc player with a built-in radio receiver) according to one embodiment of the present invention. The radio receiver and compact disc player 9 comprises: a player 2 which is used to read information from a compact disc 1, to play back audio signals, and to read lead-in information from the CD (compact disc); a radio receiver 8 for receiving radio broadcasts; an amplifier 5 for amplifying audio signals from the player 2 and from the radio receiver 8 and for outputting the amplified signals to a speaker 7; a microprocessor 4 for controlling the player 2, the radio receiver 8 and the amplifier 5, and for controlling security-related operations; and an electrically erasable programmable read-only memory (EEPROM) 3 for storing information that is used to release the security operation. The microprocessor 4 is directly connected to a battery on one end and via an ignition switch IGSW1 on another end. The microprocessor 4 monitors the condition of connection to the battery. The microprocessor 4 also contains a ROM (read-only memory) in which programs and the TOC contents of the master disc are stored.
The CD player 9 is mounted detachably, for example, in a console panel of a motor vehicle. Connectors 51 and 52 are respectively provided on a power line between the CD player 9 and the battery B and on a signal line between the CD player 9 and the speaker 7. When the CD player 9 is mounted in the console panel, the power line and the signal line are electrically connected by the connectors 51 and 52, respectively. When the CD player 9 is removed from the console panel, the power line and the signal line are disconnected at the connectors 51 and 52, respectively.
The EEPROM 3 is a memory that can electrically retain the stored contents without requiring a power supply.
When the driver of the vehicle turns on the ignition switch IGSW1, power from the battery B1 is supplied to an ignition circuit 53 which then impresses a pulse voltage to a spark ignition internal-combustion engine 54 to generate the spark for ignition.
Next, the operation of the audio equipment in one embodiment of the present invention will be described below. FIG. 2 is a schematic diagram showing the arrangement on the front of the automotive audio equipment (radio receiver and CD player with a built-in radio receiver).
A disc insertion slot 11 for insertion of a compact disc, a display section 12 for presenting various displays, and a plurality of switches for various operations are arranged on the front panel of the radio receiver and CD player 9 which has a built-in radio receiver.
The display section 12 displays information in accordance with the operation of the player 2 and the radio receiver 8 such as a number of music to play on the compact disc, playing time, volume, reception frequency, reception band (AM, FM), etc.
Reference numerals 13 and 14 are switches for adjusting the volume, tone, balance, and fader (front/rear balance). The desired item of adjustment (volume, tone, balance, or fader) is selected with a mode switch 15 and is increased or decreased by the adjusting switches 13 and 14. The desired item of adjustment changes each time the mode switch 15 is operated, and when the mode switch 15 is left unoperated for more than a predetermined time, the mode automatically returns to the volume adjustment mode.
Reference numerals 16 and 17 are source selection switches in which the player 2 is selected as the source of sound when the switch 16 is operated and the radio receiver 8 is selected when the switch 17 is operated.
Reference numeral 18 indicates an array of numeric switches which are used to select music programs during the operation of the player 2, and the numeric switches are also used to select preset radio stations during the operation of the radio receiver 8. For example, during the operation of the player 2, when the "3" numeric switch is operated, followed by a playback switch 23 described hereinafter, program No. 3 on the CD is played back. Likewise, during the operation of the radio receiver 8, when the "2" numeric switch is operated momentarily (for example, for less than 2 seconds), the reception frequency stored in the memory corresponding to the No. 2 numeric switch is read out of that memory and the radio receiver 8 is automatically tuned in to the designated frequency. On the other hand, when the "2" numeric switch is pressed and held down for a while (for example, for more than two seconds), the frequency currently being received is written into the memory corresponding to the "2" numeric switch.
Reference numeral 19 denotes a band selection switch which is used to switch between reception bands (AM and FM) of the radio receiver 8. Reference numerals 20 and 21 are UP and DOWN switches used to change the reception frequency. When the DOWN switch 20 is operated, the reception frequency decreases, and when the UP switch 21 is operated, the reception frequency increases.
Reference numeral 22 denotes an eject switch which, when operated, the compact disc loaded in the player 2 is ejected through the disc insertion slot 11. Reference numeral 23 is a play switch for the player 2, and when this switch is operated during the playback of a compact disc, the playback stops, and when it is operated while the playback is being stopped, the playback of the compact disc starts again.
Next, description is made of the security-related operations for the audio equipment according to the above embodiment of the present invention.
Security Operation
When the CD player 9 with a built-in radio receiver, while being set in a security mode, is removed from a vehicle and installed in another vehicle, the security function is activated. In other words, when the CD player 9, with a built-in radio receiver, is set in the security mode, is once removed from the battery and then connected again to the battery, the security function is activated. More specifically, when the microprocessor 4 has detected a change in the battery connection condition, that is the change of battery connection condition from a variation in power supply thereby detecting removed condition of the CD player 9, the security system is activated. Once the security system is activated, the CD player 9 with a built-in radio receiver is inoperable. That is, the microprocessor 4 does not accept any switch operation except a prescribed operation of designated switches.
To release this inoperable condition, a designated disc set by the user must be inserted or the CD player 9 with a built-in radio receiver must be taken to the manufacturer or dealer where a master disc is maintained and is inserted, so as to release the inoperable condition and make the CD player 9 with a built-in radio receiver operable.
More specifically, when the CD player 9 with a built-in radio receiver is once removed from the battery while it is set in the security mode (the TOC data of the identification (ID) disc is stored in the EEPROM 3 in the CD player 9 with a built-in radio receiver), and if power is turned on again, the CD player 9 with a built-in radio receiver cannot be operated and the display section 12 presents a display to the effect that the equipment is inoperable due to the activation of the security system ("SEC" illuminates for two seconds). Then, an indication requesting disc insertion appears ("DISC" stays lit until a disc is inserted). When the ID disc is inserted through the disc insertion slot 11, the security function is released, and an indication indicating that the CD player 9 with a built-in radio receiver is now made operable appears ("OK" illuminates for two seconds), after which the disc is ejected and the equipment enters a normal operation mode (for operation of the player 2 or the radio receiver 8).
On the other hand, when a compact disc other than the ID disc (or a disc whose TOC data cannot be read correctly) is inserted through the disc insertion slot 11, the display section 12 displays the unreadable condition along with the number of times that the disc has been inserted ("ERR n" illuminates for two seconds), after which the disc is ejected and the indication requesting disc insertion appears once again ("DISC" stays lit until a disc is inserted).
When compact discs other than the ID disc have been inserted through the disc insertion slot 11 five times in succession, the display section 12 then presents an indication requesting the user to recheck whether the compact discs inserted are the ID disc ("COOL" stays lit for one hour after the equipment was reconnected to the battery), after which the disc is ejected once and (when one hour has elapsed after reconnection to the battery) the indication requesting disc insertion appears once again ("DISC" stays lit until the disc is inserted). In this case, if designated switches are operated in a specified manner (the source selection switch 16 and the "1" and the "2" numeric switches 18 are depressed simultaneously), an indication indicating the faulty condition and suggesting that the equipment be taken to the dealer is displayed ("HELP" stays lit until power is turned off), and the ID disc cancel mode is terminated. Since the waiting time before the ID disc can be inserted for the sixth time is long, the user may decide that he cannot wait that long time and may give up trying to release the inoperable condition by himself after attempting five times. The above arrangement is made so as to encourage the user to let the dealer immediately release the inoperable condition.
Further, when compact discs other than the ID disc have been inserted through the disc insertion slot 11 ten times in succession, again the indication indicating the faulty condition and suggesting that the equipment be taken to the dealer is displayed ("HELP" stays lit until power is turned off), and the ID disc cancel mode is terminated.
Once the indication of the faulty condition and suggestion that the equipment be taken to the dealer is displayed, the CD player 9 with a built-in radio receiver remains inoperable even if the power is turned off, and the inoperable condition cannot be released unless a release operation is performed using the master disc at the dealer. That is, the insertion of discs other than the ID disk is treated as a simple mistake on the user's side up to nine times, but when the attempt has failed for the tenth time in succession, the attempt is judged as being an act by a burglar. This arrangement enhances theft prevention performance.
Setting Of Security Mode and Setting of ID Disc
The security mode is set by the user for writing the TOC data of the identification (ID) disc into the EEPROM 3 contained in the CD player 9 with a built-in radio receiver (ID disc setting operation). That is, the microprocessor 4 determines whether or not the equipment is set in the security mode, by checking whether or not data is stored in the EEPROM 3 (i.e., whether it is in the initial condition (usually, "0" is stored)). The ID disc setting operation is performed by first setting the mode to the ID disc setting mode by performing a prescribed operation when power is turned on to the CD player 9 with a built-in radio receiver, and then inserting a compact disc to be used as the ID disc through the disc insertion slot 11 in accordance with the indication displayed on the display section 12 of the CD player 9 with a built-in radio receiver.
More specifically, at power on, first the source selection switch 16 and the "1" numeric switch 18 are depressed simultaneously to enter the security setting mode, upon which the display section 12 presents a display indicating that the security setting mode has been entered ("SEC" illuminates for two seconds), and if any compact disc is already loaded, that compact disc is ejected. Next, an indication which requests disc insertion is displayed ("DISC" stays lit until a disc is inserted). When the compact disc to be set as the ID disc is inserted through the disc insertion slot 11, the TOC data of the compact disc is read and written into the EEPROM 3 as identification data. After an indication that the completion of the ID disc setting operation is displayed ("SEC" illuminates for two seconds), the disc is ejected once and the ID disc setting mode is terminated. The equipment then enters a normal operation mode (for operation of the player 2 or the radio receiver 8).
When a compact disc not suitable for the ID disc, for example a compact disc whose TOC data cannot be read due to scratches, has been inserted as an attempt to set it as the ID disc, that is, when TOC data has not been able to be read from the compact disc inserted in the disc insertion slot 11, an indication of the unreadable condition is displayed on the display section 12 ("ERR" illuminates for two seconds) at the first attempt, after which the disc is ejected and the indication requesting disc insertion appears once again ("DISC" stays lit until a disc is inserted).
If the TOC data read failure has occurred twice in succession, an indication requesting a disc change is displayed on the display section 12 ("CHANGE" illuminates for two seconds), after which the disc is ejected and the indication requesting disc insertion appears once again ("DISC" stays lit until the disc is inserted).
Clearing the Security Mode
The security mode is cleared by erasing (initializing) the identification data stored in the EEPROM 3. That is, the microprocessor 4 erases the identification data stored in the EEPROM 3 when a prescribed operation is performed. The prescribed operation is accomplished by first setting the mode to an ID disc cancel mode by performing a designated operation when power is turned on to the CD player 9 with a built-in radio receiver, and then inserting the previously set ID disc or the master disc maintained at the dealer through the disc insertion slot 11 in accordance with the indication on the display section 12 of the CD player 9 with a built-in radio receiver.
More specifically, at power on, first the source selection switch 16 and the numeric switch "2" are depressed simultaneously to enter the security cancel mode, upon which the display section 12 presents an indication that the security cancel mode has been entered ("SEC" illuminates for two seconds), and if any compact disc is already loaded, that compact disc is ejected. Next, an indication requesting disc insertion is displayed ("DISC" stays lit until a disc is inserted). When the ID disc (or the master disc) is inserted through the disc insertion slot 11, the TOC data written in the EEPROM 3 is erased. After an indication indicating the completion of the ID disc cancel operation is displayed ("CANCEL" illuminates for two seconds), the disc is ejected once and the ID disc cancel mode is terminated. The equipment then enters a normal operation mode (for operation of the player 2 or the radio receiver 8).
On the other hand, when a compact disc other than the ID disc (or a disc whose TOC data cannot be read correctly) is inserted through the disc insertion slot 11, the display section 12 displays the unreadable condition along with the number of times that the disc has been inserted ("ERR n" illuminates for two seconds), after which the disc is ejected once and an indication requesting disc insertion appears once again ("DISC" stays lit until a disc is inserted).
When compact discs other than the ID disc have been inserted through the disc insertion slot 11 five times in succession, the display section 12 then presents an indication requesting the user to recheck whether any of the compact discs inserted are the ID disc ("COOL" flashes five times), after which the disc is ejected once and the indication requesting disc insertion appears once again ("DISC" stays lit until a disc is inserted).
Further, when compact discs other than the ID disc have been inserted through the disc insertion slot 11 ten times in succession, an indication indicating the faulty condition and a suggestion that the equipment be taken to the dealer is displayed ("HELP" stays lit until power is turned off), and the ID disc cancel mode is terminated.
Also, the CD player 9 with a built-in radio receiver remains inoperable even if the power is turned off once, and the inoperable condition cannot be released unless a release operation is performed using the master disc maintained at the dealer. That is, the insertion of discs other than the ID disk is treated as a simple mistake on the user's side up to nine times. but when the attempt has failed for the tenth time in succession, the attempt is judged as being an act by a burglar. This arrangement enhances theft prevention performance.
Master Input Mode (Release of Inoperable Condition at Dealer)
Once the indication of the faulty condition and suggestion that the equipment be taken to the dealer ("HELP" stays lit until power is turned off) has been presented on the display section 12 after failing to clear the security mode or after failing to release the inoperable condition, the inoperable condition can be released only by inserting the master disc maintained at the dealer through the disc insertion slot. In this case, the security mode is also cleared. That is, the data stored in the EEPROM 3 is erased.
Specifically, at power on, an indication indicating that the master input mode has been entered is displayed on the display section 12 ("HELP" illuminates). By performing a prescribed operation (simultaneous depression of the source selection switch 16 and the "3" and "4" numeric switches 18), the inoperable condition can be released by using the master disc, and an indication requesting insertion of the master disc is displayed ("DISC" keeps flashing until the disc is inserted). When the master disc is inserted through the disc insertion slot 11, the inoperable condition of the CD player 9 with a radio receiver is released, and at the same time, the TOC data written in the EEPROM 3 is erased. After an indication of the completion of the inoperable condition releasing operation is displayed ("OK" illuminates for two seconds), the disc is ejected once and the master disc input mode is terminated. The equipment then enters a normal operation mode (for operation of the player 2 or the radio receiver 8).
On the other hand, if a disc other than the master disc is inserted through the disc insertion slot 11, the display section 12 displays the unreadable condition along with the number of times that the disc has been inserted ("ERR n" illuminates for two seconds), after which the disc is ejected once and the display requesting disc insertion appears once again ("DISC" keeps flashing until a disc is inserted).
Further, when compact discs other than the ID disc have been inserted through the disc insertion slot 11 for an integral multiple of 5 times (5 times, 10 times, . . . ) in succession, the condition returns to the same condition as at power on, and the display 12 once again displays the indication that the master input mode has been entered ("HELP" illuminates), requiring that the prescribed operation be performed once again if the inoperable condition is to be released.
Next, description is made of the processing that the microprocessor 4 carries out to accomplish the above-described operations.
FIG. 3 is a flowchart illustrating the main routine of the processing that the microprocessor 4 performs. When the CD player 9 with a built-in radio receiver is put into operation by turning on the accessory switch of a vehicle (by operating the ignition switch), or by turning on the power switch on the CD player 9 with a built-in radio receiver, the process is started and the operation first proceeds to step M1.
In step M1, a decision is made as to whether or not an ID disc setting has already been performed. If no ID disc setting has yet been performed, a branch is made to the processing of the ID disc setting mode. If there already exists a valid ID disc setting, the process moves to step M2. This aforementioned decision is made based on whether the TOC data of the ID disc is stored in the EEPROM 3.
In step M2, a decision is made as to whether the connection between the CD player 9 with a built-in radio receiver and the battery B has ever been cut off. If the answer to the decision is NO, a branch is made to the processing of the ID disc cancel mode. If the answer is YES, the process proceeds to step M3. This decision is made by the microprocessor 4 which monitors the voltage across the connection terminals with the battery B and acknowledges a voltage drop condition if any voltage drop is detected.
In step M3, a decision is made as to whether the mode is the master carry-in mode. If it is not the master carry-in mode, a branch is made to the processing of the inoperable condition releasing mode. If it is the master carry-in mode, a branch is made to the processing of the master input processing mode. This decision is made by the microprocessor 4 which acknowledges a failure of inoperable condition releasing operation, a failure of ID disc cancel operation, etc.
When the CD player 9 with a built-in radio receiver has been placed in operation with the above processing,
(a) If the ID disc is not set, a branch is made to the processing of the ID setting mode,
(b) If the ID disc is set and if no disconnection of the CD player 9 with a built-in radio receiver from the battery B has been detected, a branch is made to the processing of the ID disc cancel mode,
(c) If the ID disc is set, if a disconnection of the CD player 9 with a built-in radio receiver from the battery B has ever been detected, and if the mode is not the master carry-in mode, a branch is made to the processing of the inoperable condition releasing mode,
(d) If the mode is the master carry-in mode, a branch is made to the processing of the master input processing mode.
Next, the processing of the ID disc setting mode (which also includes the security mode setting processing) will be described. FIG. 4 is a flowchart illustrating the processing of the ID disc setting mode that the microprocessor 4 performs.
When a branch is made from the main routine to the processing of the ID disc setting mode, the processing starts and proceeds to step S1 where a decision is made as to whether a mode-off operation has been performed. A mode-off operation is an operation other than setting initiating operations, and refers to any normal operation of the CD player 9 with a built-in radio receiver, such as the operation of the source selection switches 16, 17, play switch 23, or the inserting operation of a compact disc into the disc insertion slot 11 etc. If it is decided that a mode-off operation has been performed, the ID disc setting operation (data writing to the EEPROM 3) is skipped, and the process moves to the processing of the normal operation to control the operation of the player 2 and the radio receiver 8. Otherwise, the process moves to step S2.
In step S2, a decision is made as to whether an ID disc setting initiating operation has been performed. If the answer to the decision is YES, the process proceeds to step S3. If the answer is NO, the operation proceeds to the processing of the normal operation. The ID disc setting initiating operation is performed by operating designated switches in a prescribed manner. In this embodiment, as previously described, simultaneous depression of the source selection switch 16 and the "1" numeric switch 18 constitutes the ID disc setting initiating operation. Decisions in steps S1 and S2 are made by performing interrupt processing to detect the operation of the various switches or the inserting operation of a compact disc into the disc insertion slot 11. With these interrupts, the process moves to the next step.
In step S3, an indication that the ID disc setting mode has been entered is displayed ("SEC" illuminates for two seconds), after which the process proceeds to step S4. In step S4, if any disc is already loaded in the player 2, the disc is ejected. In step S5, an indication ("DISC") directing the insertion of a compact disc is displayed, and the processing in step S5 and S6 is repeated until it is judged in step S6 that a compact disc has been inserted. When a compact disc has been inserted, the process moves to step S7, where a decision is made as to whether the TOC data of the inserted compact disc can be read correctly. That is, whether the compact disc is suitable for the ID disc. If the data can be read correctly, the process moves to step S8. Otherwise, the process moves to step S11.
In step S8, the TOC data of the compact disc is written into the EEPROM 3 as the identification data. Then, in step S9, an indication of the completion of the ID disc setting operation is displayed ("SEC" illuminates for two seconds), and in step S10, the compact disc is ejected, after which the process moves to the processing of the normal operation.
On the other hand, in step S11, an indication that the TOC data of the compact disc cannot be read correctly is displayed ("ERR" illuminates for two seconds), and in step S12, the compact disc is ejected, after which the process moves to step S13.
In step S13, it is judged whether the TOC data reading has failed twice in succession. If it has failed twice in succession, then the disc is judged as being unsuitable for the ID disc because of scratches or the like, and the process moves to step S14, where an indication requesting a disc change is displayed ("CHANGE" illuminates for two seconds). If the reading failure is not the second occurrence in succession, the process returns to step S5 to repeat the processing.
Next, the processing of the ID disc cancel mode (which also includes the security operation mode releasing operation) will be described. FIG. 5 is a flowchart illustrating the processing of the ID disc cancel mode that is performed by the microprocessor 4.
When a branch is made from the main routine to the processing of the ID disc cancel mode, the processing starts with step P1 where a decision is made as to whether a mode-off operation has been performed. A mode-off operation, as described in the processing of the ID disc setting mode, is an operation other than setting initiating operations, and refers to any normal operation of the CD player 9 with a built-in radio receiver, such as the operation of the source selection switches 16, 17, play switch 23, or the inserting operation of a compact disc into the disc insertion slot 11. If it is decided that a mode-off operation has been performed, the ID disc cancel operation (erasure of data in the EEPROM 3) is skipped, and the process moves to the processing of the normal operation to control the operation of the player 2 and the radio receiver 8. Otherwise, the process proceeds to step S2.
In step P2, a decision is made as to whether an ID disc cancel initiating operation has been performed. If the answer to the decision is YES, the process moves to step P3. If the answer is NO, the operation proceeds to the processing of the normal operation. The ID disc cancel initiating operation is performed by operating designated switches in a prescribed manner. In this embodiment, as previously described, simultaneous depression of the source selection switch 16 and the "2" numeric switch 18 constitutes the ID disc cancel initiating operation. Decisions in steps P1 and P2 are made by servicing interrupts to detect the operation of the various switches or the inserting operation of a compact disc into the disc insertion slot 11. With these interrupts, the process moves to the appropriate processing.
In step P3, an indication that the ID disc cancel mode has been entered is displayed ("SEC" illuminates for two seconds), after which the process moves to step P4. In step P4, any disc that is already loaded in the player 2 is ejected. In step P5, an indication ("DISC") directing a user to insert a compact disc is displayed, and the processing in step P5 and P6 is repeated until a determination is made in step P6 that a compact disc has been inserted. When a compact disc has been inserted, the process moves to step P7, where a decision is made as to whether or not the TOC data of the inserted compact disc matches the TOC data (the TOC data of the ID disc) stored in the EEPROM 3 or the master disc TOC data permanently stored in the ROM of the microprocessor 4. If the TOC data matches, the process moves to step P8 to erase the data stored in the EEPROM 3. Then, in step P9, an indication that the completion of the ID disc cancel operation is displayed ("CANCEL" illuminates for two seconds), and in step P10, the compact disc is ejected. Then the process moves to normal operation processing.
In step P11, a determination is made as to whether a TOC data mismatch has occurred five times or ten times in succession, and in step P14, it is determined whether a TOC data mismatch has occurred ten times in succession. If the occurrence of TOC data mismatch is the tenth time in succession, the process moves to step P15, where an indication of the faulty condition and suggestion that the equipment be taken to the dealer is displayed ("HELP" stays lit until power is turned off). Then, in step P16, the compact disc is ejected and the process moves to the processing of the master input mode.
On the other hand, if the occurrence of TOC data mismatch is the fifth time in succession, the process moves to step P17, where an indication requesting the user to recheck whether the compact disc inserted is the ID disc is displayed ("COOL" flashes five times). Then, in step P18, the compact disc is ejected and the process returns to step P2 to repeat the processing.
If the number of occurrences of the TOC data mismatch is neither 5 or 10 times in succession, the process moves to step P12, where an indication of the unreadable condition or indication that the inserted disc is not the ID disc and also indication of the number of occurrences, is displayed ("ERR n" illuminates for two seconds). Then, in step P13, the compact disc is ejected and the process returns to step P5 to repeat the processing.
Next, the processing of the inoperable condition releasing mode will be described. FIG. 6 is a flowchart illustrating the processing of the inoperable condition releasing mode that is performed by the microprocessor 4.
When a branch is made from the main routine to the processing of the inoperable condition releasing mode, the processing starts with step Q1 where any disc which is already loaded in the player 2 is ejected. In step Q2, an indication directing the insertion of a compact disc is displayed ("DISC" illuminates), and the processing in step Q2 and Q3 is repeated until it is determined in step Q3 that a compact disc has been inserted. When a compact disc has been inserted, the process moves to step Q4, where a decision is made as to whether or not the TOC data of the inserted compact disc matches the TOC data (the TOC data of the ID disc) stored in the EEPROM 3 or the master disc TOC data non-erasably and permanently stored in the ROM of the microprocessor 4. If the TOC data matches, the process moves to step Q5 to release the inoperable condition (by erasing the memory that retains the removal from the battery B), and an indication that the completion of the inoperable condition releasing operation has been reached is displayed ("OK" illuminates for two seconds). Then, the compact disc is ejected in step Q6, after which the process moves to the processing of the normal operation.
In step Q7, determination is made as to whether the TOC data mismatch has occurred five times or ten times in succession, and in step Q8, it is determined whether the TOC data mismatch has occurred ten times in succession. If the occurrence of the TOC data mismatch is the tenth time in succession, the process moves to step Q15, where an indication of the faulty condition and suggestion that the equipment be taken to the dealer is displayed ("HELP" stays lit until power is turned off). Then, the compact disc is ejected in step Q16, after which the process moves to the processing of the master input mode.
On the other hand, if the occurrence of the TOC data mismatch is the fifth time in succession, the process moves to step Q11, where an indication requesting the user to recheck whether the compact disc inserted is the ID disc is displayed ("COOL" flashes five times). Then, the compact disc is ejected in step Q12. In step Q13, a decision is made as to whether an operation for forced transfer to the master input mode has been performed. If the answer to the decision is YES, the process moves to step Q15. Otherwise, the process moves to step Q14, where a determination is made as to whether one hour has elapsed since the CD player 9 with a built-in radio receiver was reconnected to the battery B. The processing in steps Q11 to Q13 is repeated until one hour has elapsed. When one hour has elapsed, the process returns to step Q1 to repeat the processing. The operation for forced transfer to the master input mode is performed by operating designated switches in a prescribed manner. In this embodiment, as previously described, simultaneous depression of the source selection switch 16 and the "1" and the "2" numeric switches 18 constitutes the operation for forced transfer to the master input mode.
If the number of occurrences of the TOC data mismatch is neither 5 nor 10 in succession, the process moves to step P12, where an indication that the unreadable condition or indication that the inserted disc is not the ID disc and also an indication of the number of occurrences is displayed ("ERR n" illuminates for two seconds). Then, the compact disc is ejected in step Q10, and the process returns to step Q2 to repeat the processing.
Next, the processing of the master input mode will be described. FIG. 7 is a flowchart illustrating the processing of the master input mode that is performed by the microprocessor 4.
When a branch is made from the main routine to the processing of the master input mode, the processing starts with step R1 where an indication that the master input mode has been entered is displayed ("HELP" illuminates for two seconds). Then, the process moves to step R2.
In step R2, a decision is made as to whether a master input initiating operation has been performed. If the answer to the decision is YES, the process moves to step R3. Otherwise, the processing in steps R1 and R2 is repeated until the initiating operation has been performed. The master input initiating operation is performed by operating designated switches in a prescribed manner. In this embodiment, as previously described, simultaneous depression of the source selection switch 16 and the "3" and "4" numeric switches 18 constitutes the master input initiating operation.
In step R3, any disc which is already loaded in the player 2 is ejected. In step R3, an indication ("DISC") directing the insertion of a compact disc is displayed, and the processing in step R3 and R4 is repeated until it is judged in step R4 that a compact disc has been inserted. When a compact disc has been inserted, the process moves to step R5.
In step R5, a decision is made as to whether or not the TOC data of the inserted compact disc matches the master disc TOC data which is permanently stored in the ROM of the microprocessor 4. If the TOC data matches, the process moves to step R6 to erase the data stored in the EEPROM 3. In step R7, an indication of the completion of the master input processing is displayed ("OK" illuminates for two seconds). Then, the compact disc is ejected in step R8, after which the process moves to the processing of the normal operation.
If the TOC data does not match, the process moves to step R9 to determine whether a TOC data mismatch has occurred an integral multiple of 5 times in succession. If the TOC data mismatch has occurred an integral multiple of 5 times in succession, the process moves to step R10, where the compact disc is ejected and, after which, the process returns to step R1 to repeat the processing. On the other hand, if the number of occurrences of TOC data mismatch is not an integral multiple of 5 times in succession, the process proceeds to step R11, where an indication of the unreadable condition or an indication that the inserted disc is not the master disc and also an indication of the number of occurrences is displayed ("ERR n" illuminates for two seconds). Then, the compact disc is ejected in step P12, and the process returns to step R3 to repeat the processing.
With the above processing, the security operation, the setting of security mode (ID disc setting), releasing of the security mode (ID disc cancel), can be accomplished.
As described in detail above for the present embodiment, an anti-theft system for an automotive CD player with a built-in radio receiver is constructed using a compact disc itself as the key. This construction achieves an easy-to-operate anti-theft system free from the inconvenience associated with the use of a secret identification code.
In the present embodiment, only one ID disc can be set, but it is also possible to increase the anti-theft performance by making provisions so that a plurality of ID discs can be set and so that the inoperable condition, the security mode, cannot be released until all the ID discs have been inserted in the player 2. Alternatively, provisions may be made so that the inoperable condition, the security mode, can be released by inserting any one of the plurality of ID discs. In this case, for example, each authorized user of a vehicle maintains one of the ID discs and, by using the ID disc each user maintains, the user can release the inoperable condition. Such functional modifications can be achieved by making minor modifications to the portion of the processing contents of the microprocessor 4 which is responsible for the ID disc setting and to the portion which is responsible for matching the inserted compact disc against the TOC data stored in the EEPROM 3.
Before proceeding to a detailed description of another embodiment of the invention, the signal recording format of the mini disc will be described briefly. FIG. 16 is a diagram for illustrating the recording format of the mini disc.
There are three basic types of mini discs: a playback-only premastered disc which cannot be rewritten (FIG. 16(A)); a recordable disc which allows writing and rewriting (FIG. 16(B)); and a hybrid disc which is partially not-rewritable and partially writable and rewritable (FIG. 16(C)).
The premastered disc comprises a lead-in area 131 and a data area 132, as shown in FIG. 16(A). The TOC (Table Of Contents) data and the data specific to the disc (number of music programs, start positions of programs, playing times, etc.), are recorded in the lead-in area 131. Data such as music is recorded in the data area 132. To produce the premastered disc, a mold called a stamper is used and a resin (polycarbonate or the like) is injection molded to form a disc (including pits and lands on the signal surface). Then aluminum or the like is evaporated on the disc surface so as to provide a reflective film. The disc is therefore not-writable and not-rewritable.
The recordable disc has a lead-in area 141, a user TOC area 142, and a data area 143, as shown in FIG. 16(B). In the lead-in area 141, data indicating the positions of the user TOC area 142 and the writable and rewritable data area 143 and data indicating that the disc is a recordable disc are recorded using a manufacturing process similar to that of the premastered disc. Such data, however, is substantially the same on all recordable discs and cannot be used as data to identify a particular disc. Data recorded by a user is stored in the data area 143, and the user TOC data (number of music programs, start positions of music programs, playing times, etc.) for the data recorded in the data area 143 is recorded in the user TOC area 142. A magnetic film is formed on the user TOC area 142 and data area 143. By applying a magnetic field and illuminating laser light, magnetism is retained in the magnetic film to record data. Then by illuminating a laser beam, the magnetism polarizes the reflected light, from which the data can be read.
The hybrid disc comprises a lead-in area 151, not-rewritable data area 152, a user TOC area 154, and a writable and rewritable data area 153 as shown in FIG. 16(c). In the lead-in area 151, data, such as the TOC data, which is data specific to the disc (number of music programs, positions of music programs, playing times, etc. recorded in the not-rewritable data area 152), data indicating the positions of the not-rewritable data area 152, user TOC area 154, writable and rewritable data area 153, and data indicating that the disc is a hybrid disc are recorded using a manufacturing process similar to that for the premastered disc. Further, data such as music is recorded in the not-rewritable data area 152 using a manufacturing process similar to that of the premastered disc.
Like the recordable disc, data (such as music) recorded by a user is recorded in the data area 153, while the user TOC data for the data recorded in the data area 153 is recorded in the user TOC area 152. The hybrid disc is manufactured using the manufacturing processes of both the premastered disc and the hybrid disc.
Accordingly, discrimination among these discs can be accomplished by referencing the data recorded in the lead-in area 151. The premastered disc and the hybrid disc are suitable for identification data setting since the data for identifying the recording medium is unalterable, while the recordable disc is unsuitable for identification data setting since the data for identifying the recording medium is alterable.
Next, a security system according to the present invention will be described below. According to the security system of the present embodiment, the user selects a particular mini disc and the contents (TOC data) recorded in the lead-in area 131, 151 are written into a memory, for example, a rewritable ROM (EEPROM) or the like, contained in the audio equipment. Then, the TOC data of the inserted mini disc is compared with the contents of the memory, and when they match, the audio equipment is made operable. Writing into the ROM is performed by using a ROM writer previously built in the audio equipment. Thus, by performing a prescribed operation, the contents recorded in the lead-in area 131, 151 of the inserted mini disc are written into the ROM contained in the audio equipment.
FIG. 9 shows a block diagram of audio equipment (a mini-disc player with a built-in radio receiver) according to another embodiment of the present invention. The mini-disc player 109 with a built-in radio receiver comprises: a player 102 which is used to read information from a mini disc 101, to play back audio signals, and to read lead-in information from the MD (mini disc); a radio receiver 108 for receiving radio broadcasts; an amplifier 105 for amplifying audio signals from the player 102 and from the radio receiver 108 for outputting the amplified signals to a speaker 107; a microprocessor 104 for controlling the player 102, the radio receiver 108, and the amplifier 105, and for controlling security-related operations; and an electrically erasable programmable read-only memory (EEPROM) 103 for storing information that is used to release the security operation. The microprocessor 104 is directly connected to a battery on one end and via an ignition switch IGSW1 on another end. The microprocessor 4 monitors the condition of connection to the battery. The microprocessor 104 also contains a ROM (read-only memory) in which programs and the TOC contents of the master disc are stored.
The MD player 109 is mounted detachably, for example, in a console panel of a motor vehicle. Connectors 151 and 152 are respectively provided on a power line between the MD player 109 and the battery B1 and on a signal line between the MD player 109 and the speaker 107. When the MD player 109 is mounted in the console panel, the power line and the signal line are electrically connected by the connectors 151 and 152, respectively. When it is removed from the console panel, the power line and the signal line are disconnected at the connectors 151 and 152, respectively.
The EEPROM 103 is a memory that can electrically retain its stored contents without requiring power supply.
When the driver of the vehicle turns on the ignition switch IGSW1, power from the battery B1 is supplied to an ignition circuit 153 which then impresses a pulse voltage to a spark ignition internal-combustion engine 154 to generate the spark for ignition.
Next, the operation of the audio equipment in one embodiment of the present invention will be described below. FIG. 10 is a schematic diagram showing the arrangement on the front of the automotive audio equipment (the MD player with a built-in radio receiver).
A disc insertion slot 111 for insertion of a mini disc, a display section 112 for presenting various displays, and a plurality of switches for various operations are arranged on the front panel of the MD player 109 which has a built-in radio receiver.
The display section 112 displays information, in accordance with the operation of the player 102 and the radio receiver 108 such as number of music to play on the mini disc, playing time, volume, reception frequency, reception band (AM, FM), etc.
Reference numerals 113 and 114 denote adjusting switches for adjusting the volume, tone, balance, and fader (front/rear balance). The desired item of adjustment (volume, tone, balance, or fader) is selected with a mode switch 15 and is increased or decreased by the adjusting switches 113 and 114. The desired item of adjustment changes in order each time the mode switch 115 is operated, and when the mode switch 115 is left unoperated for more than a predetermined time, the mode automatically returns to the volume adjustment mode.
Reference numerals 116 and 117 denote source selection switches in which the player 102 is selected as the source of sound when the switch 116 is operated and the radio receiver 108 is selected when the switch 117 is operated.
Reference numeral 118 indicates an array of numeric switches which are used to select music programs during the operation of the player 102, and the numeric switches are also used to select preset radio stations during the operation of the radio receiver 108. For example, during the operation of the player 102, when the "3" numeric switch is operated, followed by a playback switch 123 described hereinafter, program No. 3 on the MD is played back. Likewise, during the operation of the radio receiver 108, when the "2" numeric switch is operated momentarily (for example, for less than 2 seconds), the reception frequency stored in the memory corresponding to the No. 2 numeric switch is read out of that memory and the radio receiver 108 is automatically tuned in to the designated frequency. On the other hand, when the "2" numeric switch is pressed and held down for a while (for example, for more than two seconds), the frequency currently being received is written into the memory corresponding to the "2" numeric switch.
Reference numeral 119 denotes a band selection switch which is used to switch between reception bands (AM and FM) of the radio receiver 108. Reference numerals 120 and 121 are UP and DOWN switches used to change the reception frequency. When the DOWN switch 120 is operated, the reception frequency decreases, and when the UP switch 121 is operated, the reception frequency increases.
Reference numeral 122 denotes an eject switch which, when operated, the mini disc loaded in the player 102 is ejected through the disc insertion slot 111. Reference numeral 123 denotes a play switch for the MD player 102, and when this switch is operated during the playback of a mini disc, the playback stops, and when it is operated while the playback is being stopped, the playback of the mini disc starts again.
Next, description is made of the security-related operations for the audio equipment according to the above embodiment of the present invention.
Security Operation
When the MD player 109 with a built-in radio receiver, while being set in a security mode, is removed from the vehicle and installed in another vehicle, the security function is activated. In other words, when the MD player 109, with a built-in radio receiver, is set in the security mode, is once removed from the battery and then connected again to the battery, security function is activated. More specifically, when the microprocessor 104 has detected the battery connection condition, that is the change of battery connection condition from a variation in power supply thereby detecting removed condition of the MD player 109, the security system is activated. Once the security system is activated, the MD player 109 with a built-in radio receiver is inoperable. That is, the microprocessor 104 does not accept any switch operation except a prescribed designated operation.
To release this inoperable condition, a designated disc set by the user must be inserted or the MD player 109 with a built-in radio receiver must be taken to the manufacturer or dealer where a master disc is maintained and is inserted, so as to release the inoperable condition and make the MD player 109 with a built-in radio receiver operable.
More specifically, when the MD player 109 with a built-in radio receiver is once removed from the battery while it is set in the security mode (the TOC data of the identification (ID) disc is stored in the EEPROM 103 in the MD player 109 with a built-in radio receiver), and if power is turned on again, the MD player 109 with a built-in radio receiver cannot be operated and the display section 112 presents an indication that the equipment is inoperable due to the activation of the security system ("SEC" illuminates for two seconds). Then, an indication requesting disc insertion appears ("DISC" stays lit until a disc is inserted). When the ID disc is inserted through the disc insertion slot 111, the security condition is released, and an indication indicating that the MD player 109 with a built-in radio receiver is now capable of operation appears ("OK" illuminates for two seconds), after which the disc is ejected and the equipment enters a normal operation mode (for operation of the player 102 or the radio receiver 108).
On the other hand, when a mini disc other than the ID disc (or a disc whose TOC data cannot be read correctly) is inserted through the disc insertion slot 111, the display section 112 displays the unreadable condition along with the number of times that the disc has been inserted ("ERR n" illuminates for two seconds), after which the disc is ejected and the indication requesting disc insertion appears once again ("DISC" stays lit until a disc is inserted).
When mini discs other than the ID disc have been inserted through the disc insertion slot 111 five times in succession, the display section 112 then presents an indication requesting the user to recheck whether the mini discs inserted are the ID disc ("COOL" stays lit for one hour after the equipment was reconnected to the battery), after which the disc is ejected once and (when one hour has elapsed after reconnection to the battery) the indication requesting disc insertion appears once again ("DISC" stays lit until a disc is inserted). In this case, if designated switches are operated in a specified manner (the source selection switch 116 and the "1" and the "2" numeric switches 118 are depressed simultaneously), an indication indicating the faulty condition and suggesting that the equipment be taken to the dealer is displayed ("HELP" stays lit until power is turned off), and the ID disc cancel mode is terminated. Since the waiting time before the ID disc can be inserted for the sixth time is long, the user may decide that he cannot wait that long time and may give up trying to release the inoperable condition by himself after attempting five times. The above arrangement is made so as to encourage the user to let the dealer immediately release the inoperable condition.
Further, when mini discs other than the ID disc have been inserted through the disc insertion slot 111 ten times in succession, again the indication indicating the faulty condition and suggesting that the equipment be taken to the dealer is displayed ("HELP" stays lit until power is turned off), and the ID disc cancel mode is terminated.
Once the indication of the faulty condition and suggestion that the equipment be taken to the dealer is presented, the MD player 109 with a built-in radio receiver remains inoperable even if the power is turned off, and the inoperable condition cannot be released unless a releasing operation is performed using the master disc at the dealer. That is, the insertion of discs other than the ID disk is treated as a simple mistake on the user's side up to nine times, but when the attempt has failed for the tenth time (in succession), the attempt is judged as being an act by a burglar. This arrangement enhances theft prevention performance.
Setting of Security Mode and Setting of ID Disc
The security mode is set by the user for writing the TOC data of the identification (ID) disc into the EEPROM 103 contained in the MD player 109 with a built-in radio receiver (ID disc setting operation). That is, the microprocessor 104 determines whether or not the equipment is set in the security mode, by checking whether or not data is stored in the EEPROM 103 (i.e., whether or not it is in the initial condition (usually, "0" is stored)). The ID disc setting operation is performed by first setting the mode to the ID disc setting mode by performing a prescribed operation when power is turned on to the MD player 109 with a built-in radio receiver, and then inserting a mini disc to be used as the ID disc through the disc insertion slot 111 in accordance with the indication displayed on the display section 112 of the radio receiver and MD player 109.
More specifically, at power on, first the source selection switch 116 and the "1" numeric switch 118 are depressed simultaneously to enter the security setting mode, upon which the display section 112 presents an indication indicating that the security setting mode has been entered ("SEC" illuminates for two seconds), and if any mini disc is already loaded, that mini disc is ejected. Next, an indication which requests disc insertion is displayed ("DISC" stays lit until a disc is inserted). When the mini disc to be set as the ID disc is inserted through the disc insertion slot 111, the TOC data of the mini disc is read and written into the EEPROM 103 as identification data. After an indication that the completion of the ID disc setting operation is displayed ("SEC" illuminates for two seconds), the disc is ejected once and the ID disc setting mode is terminated. The equipment then enters a normal operation mode (for operation of the player 102 or the radio receiver 108).
When a mini disc not suitable for the ID disc, for example a mini disc whose TOC data cannot be read due to scratches, has been inserted as an attempt to set itself as the ID disc, that is, when TOC data has not been able to be read from the mini disc inserted in the disc insertion slot 111, an indication of the unreadable condition is displayed on the display section 112 ("ERR" illuminates for two seconds) at the first attempt, after which the disc is ejected and the indication requesting disc insertion appears once again ("DISC" stays lit until a disc is inserted).
If the TOC data read failure has occurred twice in succession, an indication requesting a disc change is displayed on the display section 112 ("CHANGE" illuminates for two seconds), after which the disc is ejected and the indication requesting disc insertion appears once again ("DISC" stays lit until a disc is inserted).
On the other hand, in cases where there is no problem with the disc condition itself and the TOC data can be read successfully but the inserted disc is a recordable disc in which the data for identifying the mini disc is rewritable, the display section 112 presents an indication indicating that the disc is unsuitable ("UNSUIT" illuminates for two seconds), after which the disc is ejected once and the indication requesting disc insertion appears once again ("DISC" stays lit until a disc is inserted).
Clearing the Security Mode
The security mode is cleared by erasing (initializing) the identification data stored in the EEPROM 103. That is, the microprocessor 104 erases the identification data stored in the EEPROM 103 when a prescribed operation is performed. The prescribed operation is accomplished by first setting the mode to an ID disc cancel mode by performing a designated operation when power is turned on to the MD player 109 with a built-in radio receiver, and then inserting the previously set ID disc or the master disc maintained at the dealer through the disc insertion slot 111 in accordance with the indication displayed on the display section 112 of the MD player 109 with a built-in radio receiver.
More specifically, at power on, first the source selection switch 116 and the "2" numeric switch 118 are depressed simultaneously to enter the security cancel mode, upon which the display section 112 presents an indication that the security cancel mode has been entered ("SEC" illuminates for two seconds), and if any mini disc is already loaded, that mini disc is ejected. Next, an indication requesting disc insertion is displayed ("DISC" stays lit until a disc is inserted). When the ID disc (or the master disc) is inserted through the disc insertion slot 111, the TOC data written in the EEPROM 103 is erased. After an indication indicating the completion of the ID disc cancel operation is displayed ("CANCEL" illuminates for two seconds), the disc is ejected once and the ID disc cancel mode is terminated. The equipment then enters a normal operation mode (for operation of the player 102 or the radio receiver 108).
On the other hand, when a mini disc other than the ID disc (or a disc whose TOC data cannot be read correctly) is inserted through the disc insertion slot 111, the display section 112 displays the unreadable condition along with the number of times that the disc has been inserted ("ERR n" illuminates for two seconds), after which the disc is ejected once and an indication requesting disc insertion appears once again ("DISC" stays lit until a disc is inserted).
When mini discs other than the ID disc have been inserted through the disc insertion slot 111 five times in succession, the display section 112 then presents an indication requesting the user to recheck whether any of the mini discs inserted are the ID disc ("COOL" flashes five times), after which the disc is ejected once and the indication requesting disc insertion appears once again ("DISC" stays lit until a disc is inserted).
Further, when mini discs other than the ID disc have been inserted through the disc insertion slot 111 ten times in succession, an indication indicating the faulty condition and a suggestion that the equipment be taken to the dealer is displayed ("HELP" stays lit until power is turned off), and the ID disc cancel mode is terminated.
Also, the MD player 109 with a built-in radio receiver remains inoperable even if the power is turned off once, and the inoperable condition cannot be released unless a releasing operation is performed using the master discs maintained at the dealer. That is, the insertion of a disc other than the ID disk is treated as a simple mistake on the user's side up to nine times, but when the attempt has failed for the tenth time (in succession), the attempt is judged as being an act by a burglar. This arrangement enhances theft prevention performance.
Master Input Mode (Release of Inoperable Condition at Dealer, Etc.)
Once the indication of the faulty condition and suggestion that the equipment be taken to the dealer ("HELP" stays lit until power is turned off) has been presented on the display section 112 after failing to clear the security mode or after failing to release the inoperable condition, the inoperable condition can be released only by inserting the master disc maintained at the dealer through the disc insertion slot. In this case, the security mode is also cleared. That is, the data stored in the EEPROM 103 is erased.
Specifically, at power on, an indication indicating that the master input mode has been entered is displayed on the display section 112 ("HELP" illuminates). By performing a prescribed operation (simultaneous depression of the source selection switch 116 and the "3" and the "4" numeric switches 118), the inoperable condition can be released by using the master disc, and an indication requesting insertion of the master disc appears ("DISC" keeps flashing until the disc is inserted). When the master disc is inserted through the disc insertion slot 111, the inoperable condition of the MD player 109 with a built-in radio receiver is released, and at the same time, the TOC data written in the EEPROM 103 is erased. After an indication of the completion of the inoperable condition releasing operation is displayed ("OK" illuminates for two seconds), the disc is ejected once and the master disc input mode is terminated. The equipment then enters a normal operation mode (for operation of the player 102 or the radio receiver 108).
On the other hand, when a disc other than the master disc is inserted through the disc insertion slot 111, the display section 112 displays the unreadable condition along with the number of times that the disc has been inserted ("ERR n" illuminates for two seconds), after which the disc is ejected once and the indication requesting disc insertion appears once again ("DISC" keeps flashing until a disc is inserted).
Further, when mini discs other than the master disc have been inserted through the disc insertion slot 111 for an integral multiple of 5 times (5 times, 10 times, . . . ) in succession, the condition returns to the same condition as at power on, and the display section 112 once again presents the indication that the master input mode has been entered ("HELP" illuminates), requiring that the prescribed operation be performed once again if the inoperable condition is to be released.
Next, description is made of the processing that the microprocessor 104 carries out to accomplish the above-described operations.
FIG. 11 is a flowchart illustrating the main routine of the processing that the microprocessor 104 performs. When the MD player 109 with a built-in radio receiver is put into operation by turning on the accessory switch of a vehicle (by operating the ignition switch), or by turning on the power switch on the MD player 109 with a built-in radio receiver, the process is started and the operation first proceeds to step A1.
In step A1, a decision is made as to whether or not an ID disc setting has already been performed. If no ID disc setting has yet been performed, a branch is made to the processing of the ID disc setting mode. If there already exists a valid ID disc setting, the process moves to step A2. This aforementioned decision is made based on whether the TOC data of the ID disc is stored in the EEPROM 103.
In step A2, a decision is made as to whether the connection between the MD player 109 with a built-in radio receiver and the battery B1 has ever been cut off. If the answer to the decision is NO, a branch is made to the processing of the ID disc cancel mode. If the answer is YES, the process proceeds to step A3. This decision is made by the microprocessor 104 which monitors the voltage across the connection terminals with the battery B1 and acknowledges a voltage drop condition if any voltage drop is detected.
In step A3, a decision is made as to whether the mode is the master carry-in mode. If it is not the master carry-in mode, a branch is made to the processing of the inoperable condition release mode. If it is the master carry-in mode, a branch is made to the processing of the master input processing mode. This decision is made by the microprocessor 104 which acknowledges a failure of inoperable condition release operation, a failure of ID disc cancel operation, etc.
When the MD player 109 with a built-in radio receiver has been placed in operation with the above processing,
(a) If the ID disc is not set, a branch is made to the processing of the ID setting mode,
(b) If the ID disc is set and if no disconnection of the radio MD player 109 with a built-in radio receiver from the battery B1 has been detected, a branch is made to the processing of the ID disc cancel mode,
(c) If the ID disc is set, if a disconnection of the radio MD player 109 with a built-in radio receiver from the battery B1 has ever been detected, and if the mode is not the master carry-in mode, a branch is made to the processing of the inoperable condition release mode,
(d) If the mode is the master carry-in mode, a branch is made to the processing of the master input processing mode.
Next, the processing of the ID disc setting mode (which also includes the security mode setting processing) will be described. FIG. 12 is a flowchart illustrating the processing of the ID disc setting mode that the microprocessor 104 performs.
When a branch is made from the main routine to the processing of the ID disc setting mode, the processing starts and proceeds to step B1 where a decision is made as to whether a mode-off operation has been performed. A mode-off operation is an operation other than setting initiating operations, and refers to any normal operation of the MD player 109 with a built-in radio receiver, such as the operation of the source selection switches 116, 117, play switch 123, or the inserting operation of a mini disc into the disc insertion slot 111 etc. If it is decided that a mode-off operation has been performed, the ID disc setting operation (data writing to the EEPROM 103) is skipped, and the process moves to the processing of the normal operation to control the operation of the player 102 and the radio receiver 108. Otherwise, the process moves to step B2.
In step B2, a decision is made as to whether an ID disc setting initiating operation has been performed. If the answer to the decision is YES, the process proceeds to step B3. If the answer is NO, the operation proceeds to the processing of the normal operation. The ID disc setting initiating operation is performed by operating designated switches in a prescribed manner. In this embodiment, as previously described, simultaneous depression of the source selection switch 116 and the "1" numeric switch 118 constitutes the ID disc setting initiating operation. Decisions in steps B1 and B2 are made by performing interrupt processing to detect the operation of the various switches or the inserting operation of a mini disc into the disc insertion slot 111. With these interrupts, the process moves to the next step.
In step B3, an indication indicating that the ID disc setting mode has been entered is displayed ("SEC" illuminates for two seconds), after which the process proceeds to step B4. In step B4, if any disc is already loaded in the player 102, the disc is ejected. In step B5, an indication ("DISC") directing the insertion of a mini disc is displayed, and the processing in step B5 and B6 is repeated until it is judged in step B6 that a mini disc has been inserted. When a mini disc has been inserted, the process moves to step B7, where a decision is made as to whether the inserted mini disc is a suitable disc, that is, whether the inserted disc is not a recordable disc (or whether or not the inserted disc is either a premastered disc or a hybrid disc). If it is a premastered disc or a hybrid disc (either is a suitable disc), the process proceeds to step B8. On the other hand, if it is a recordable disc (not a suitable disc), the process moves to step B12.
In step B8, a decision is made as to whether the TOC data of the inserted mini disc can be read correctly. That is, whether the mini disc is suitable for the ID disc. If the data can be read correctly, the process proceeds to step B9. Otherwise, the process proceeds to step B14. In step B9, the TOC data of the mini disc is written into the EEPROM 103 as the identification data. Then, in step B10, an indication of the completion of the ID disc setting operation is displayed ("SEC" illuminates for two seconds), and in step B11, the mini disc is ejected, after which the process moves to the processing of the normal operation.
On the other hand, in step B12, an indication that the mini disc is not a suitable disc is displayed ("UNSUIT" illuminates for two seconds), and in step B13, the mini disc is ejected, after which the process moves to step B16.
In step B14, an indication indicating that the TOC data of the mini disc cannot be read correctly is displayed ("ERR" illuminates for two seconds), after which the mini disc is ejected in step B15, and the process moves to step B16. In step B16, it is determined whether the TOC data reading has failed twice in succession. If it has failed twice in succession, then the disc is determined as being unsuitable for the ID disc because of scratches etc., and the process proceeds to step B17 where an indication requesting disc change is displayed ("CHANGE" illuminates for two seconds). If the reading failure is not the second time in succession, the process returns to step B5 to repeat the processing.
Next, the processing of the ID disc cancel mode (which also includes the security mode release operation) will be described. FIG. 13 is a flowchart illustrating the processing of the ID disc cancel mode that is performed by the microprocessor 104.
When a branch is made from the main routine to the processing of the ID disc cancel mode, the processing starts with step C1 where a decision is made as to whether a mode-off operation has been performed. A mode-off operation, as described in the processing of the ID disc setting mode, is an operation other than setting initiating operations, and refers to any normal operation of the MD player 109 with a built-in radio receiver, such as the operation of the source selection switches 116, 117, play switch 123, or the inserting operation of a mini disc into the disc insertion slot 111. If it is decided that a mode-off operation has been performed, the ID disc cancel operation (erasure of data in the EEPROM 103) is skipped, and the process proceeds to the processing of normal operation to control the operation of the player 102 and the radio receiver 108. Otherwise, the process proceeds to step C2.
In step C2, a decision is made as to whether an ID disc cancel initiating operation has been performed. If the answer to the decision is YES, the process moves to step C3. If the answer is NO, the operation proceeds to the processing of the normal operation. The ID disc cancel initiating operation is performed by operating designated switches in a prescribed manner. In this embodiment, as previously described, simultaneous depression of the source selection switch 116 and the "2" numeric switch 118 constitutes the ID disc cancel initiating operation. Decisions in steps C1 and C2 are made by servicing interrupts to detect the operation of the various switches or the inserting operation of a mini disc into the disc insertion slot 111. With these interrupts, the process moves to the next processing.
In step C3, an indication that the ID disc cancel mode has been entered is displayed ("SEC" illuminates for two seconds), after which the process moves to step C4. In step C4, any disc that is already loaded in the player 102 is ejected. In step C5, an indication ("DISC") directing a user to insert a mini disc is displayed, and the processing in step C5 and C6 is repeated until a determination is made in step C6 that a mini disc has been inserted. When a mini disc has been inserted, the process moves to step C7, where a decision is made as to whether or not the TOC data of the inserted mini disc matches the TOC data (the TOC data of the ID disc) stored in the EEPROM 103 or the master disc TOC data non-erasably stored in the ROM of the microprocessor 104. If the TOC data matches, the process moves to step C8 to erase the data stored in the EEPROM 103. Then, in step C9, an indication that the completion of the ID disc cancel operation is displayed ("CANCEL" illuminates for two seconds), and in step C10, the mini disc is ejected. Then, the process moves to the processing of the normal operation.
In step C11, a determination is made as to whether a TOC data mismatch has occurred five times or ten times in succession, and in step C14, it is determined whether a TOC data mismatch has occurred ten times in succession. If the occurrence of TOC data mismatch is the tenth time in succession, the process moves to step C15, where an indication of the faulty condition and suggestion that the apparatus be taken to the dealer is displayed ("HELP" stays lit until power is turned off). Then, in step C16, the mini disc is ejected, and the process moves to the processing of the master input mode.
On the other hand, if the occurrence of TOC data mismatch is the fifth time in succession, the process moves to step C17, where an indication requesting the user to recheck whether the mini disc inserted is the ID disc is displayed ("COOL" flashes five times). Then, in step C18, the mini disc is ejected and the process returns to step C2 to repeat the processing.
If the number of occurrences of the TOC data mismatch is neither 5 nor 10 times in succession, the process moves to step C12, where an indication of the unreadable condition or indication that the inserted disc is not the ID disc and also indication of the number of occurrences, is displayed ("ERR n" illuminates for two seconds). Then, in step C13, the mini disc is ejected and the process returns to step C5 to repeat the processing.
Next, the processing of the inoperable condition release mode will be described. FIG. 14 is a flowchart illustrating the processing of the inoperable condition release mode that is performed by the microprocessor 104.
When a branch is made from the main routine to the processing of the inoperable condition release mode, the processing starts with step D1 where any disc which is already loaded in the player 102 is ejected. In step D2, an indication directing the insertion of a mini disc is displayed ("DISC" illuminates), and the processing in step D2 and D3 is repeated until it is determined in step D3 that a mini disc has been inserted. When a mini disc has been inserted, the process moves to step D4, where a decision is made as to whether or not the TOC data of the inserted mini disc matches the TOC data (the TOC data of the ID disc) stored in the EEPROM 103 or the master disc TOC data permanently stored in the ROM of the microprocessor 104. If the TOC data matches, the process moves to step D5 to release the inoperable condition (by erasing the memory that retains the removal from the battery B1), and an indication that the completion of the inoperable condition release operation has been reached is displayed ("OK" illuminates for two seconds). Then, the mini disc is ejected in step D6, after which the process moves to the processing of the normal operation.
In step D7, determination is made as to whether the TOC data mismatch has occurred five times or ten times in succession, and in step D8, it is determined whether the TOC data mismatch has occurred ten times in succession. If the occurrence of the TOC data mismatch is the tenth time in succession, the process moves to step D15, where an indication of the faulty condition and suggestion that the apparatus be taken to the dealer is displayed ("HELP" stays lit until power is turned off). Then, the mini disc is ejected in step D16, after which the process moves to the processing of the master input mode.
On the other hand, if the occurrence of the TOC data mismatch is the fifth time in succession, the process moves to step D11, where an indication requesting the user to recheck whether the mini disc inserted is the ID disc is displayed ("COOL" flashes five times). Then, the mini disc is ejected in step D12. In step D13, a decision is made as to whether an operation for forced transfer to the master input mode has been performed. If the answer to the decision is YES, the process moves to step D15. Otherwise, the process moves to step D14, where it is determined whether one hour has elapsed since the MD player 109 with a built-in radio receiver was reconnected to the battery B1. The processing in steps D11 to D13 is repeated until one hour has elapsed. When one hour has elapsed, the process returns to step D1 to repeat the processing. The operation for forced transfer to the master input mode is performed by operating designated switches in a prescribed manner. In this embodiment, as previously described, simultaneous depression of the source selection switch 116 and the "1" and the "2" numeric switches 118 constitutes the operation for mode forced transfer to the master input mode.
If the number of occurrences of the TOC data mismatch is neither 5 or 10 in succession, the process moves to step D9, where an indication that the unreadable condition or indication that the inserted disc is not the ID disc and also an indication of the number of occurrences is displayed ("ERR n" illuminates for two seconds). Then, the mini disc is ejected in step D10, and the process returns to step D2 to repeat the processing.
Next, the processing of the master input mode will be described. FIG. 15 is a flowchart illustrating the processing of the master input mode that is performed by the microprocessor 104.
When a branch is made from the main routine to the processing of the master input mode, the processing starts with step E1 where an indication that the master input mode has been entered is displayed ("HELP" illuminates for two seconds). Then, the process moves to step E2.
In step E2, a decision is made as to whether a master input initiating operation has been performed. If the answer to the decision is YES, the process moves to step E3. Otherwise, the processing in steps E1 and E2 are repeated until the initiating operation has been performed. The master input initiating operation is performed by operating designated switches in a prescribed manner. In this embodiment, as previously described, simultaneous depression of the source selection switch 116 and the "3" and the "4" numeric switches 118 constitutes the master input initiating operation.
In step E3, an indication ("DISC") directing the insertion of a mini disc is displayed, and the processing in step E3 and E4 is repeated until it is determined in step E4 that a mini disc has been inserted. When a mini disc has been inserted, the process proceeds to step E5.
In step E5, a decision is made as to whether or not the TOC data of the inserted mini disc matches the master disc TOC data which is permanently stored in the ROM of the microprocessor 104. If the TOC data matches, the process moves to step E6 to erase the data stored in the EEPROM 103. In step E7, an indication of the completion of the master input processing is displayed ("OK" illuminates for two seconds). Then, the mini disc is ejected in step E8, after which the process moves to the processing of the normal operation.
If the TOC data does not match (in step E5), the process moves to step E9 to determine whether a TOC data mismatch has occurred an integral multiple of 5 times in succession. If the TOC data mismatch has occurred an integral multiple of 5 times in succession, the process moves to step E10, where the mini disc is ejected and, after which, the process returns to step E1 to repeat the processing. On the other hand, if the number of occurrences of TOC data mismatch is not an integral multiple of 5 times in succession, the process proceeds to step E11, where an indication of the unreadable condition or an indication that the inserted disc is not the master disc and also an indication of the number of occurrences is displayed ("ERR n" illuminates for two seconds). Then, the mini disc is ejected in step E12, and the process returns to step E3 to repeat the processing.
With the above processing, the security function activating operation, the security mode setting operation (ID disc setting operation), the security mode release operation (ID disc cancel operation), can be accomplished.
As described in detail above for the present embodiment, an anti-theft system for an automotive MD player with a built-in radio receiver is constructed using a mini disc itself as the key. This construction achieves an easy-to-operate anti-theft system free from the inconvenience associated with the use of a secret identification code.
In the present embodiment, only one ID disc can be set, but it is also possible to increase the anti-theft performance by making provisions so that a plurality of ID discs can be set and so that the inoperable condition, the security mode, cannot be released until all the ID discs have been inserted in the player 102. Alternatively, provisions may be made so that the inoperable condition, the security mode, can be released by inserting any one of the plurality of ID discs. In which case, for example, each authorized user of a vehicle maintains one of the ID discs and, by using the ID disc each user maintains, the user can release the inoperable condition. Such functional modifications can be achieved by making minor modifications to the portion of the processing contents of the microprocessor 104 which is responsible for the ID disc setting and to the portion which is responsible for matching the inserted mini disc against the TOC data stored in the EEPROM 103.
Potential for Industrial Utilization
According to the present invention, since the release of security function does not require manual input of a secret identification code, the security function can be released easily, and furthermore, there is no need to remember a secret identification code. This eliminates the possibility of a situation where the user forgets the identification code and cannot release the security function. Moreover, since the security function cannot be released without using a designated recording medium, the level of security is increased.
Furthermore, in the case of a recording medium in which data for identifying the recording medium is alterable, the data for identifying the recording medium is prohibited from being written to memory as identification data. Thus, this allows for the avoiding a situation where a recording medium, unsuitable as an identification recording medium for security, can be set as the identification recording medium for security. This prevents the data on the identification recording medium from being rewritten accidentally, leading to the inability to release the inoperable condition of the audio equipment.
It is also possible to further increase the security capability of the present invention by combining the method of the present invention with a method requiring an input of a secret identification code. | The present invention provides a security system for audio equipment which allows users to easily release a security operation without having to remember any identification numbers or codes. The present invention provides a security system for audio equipment in which audio equipment in an inoperable condition is changed into an operable condition when data recorded on a recording medium during a playback condition matches identification data stored in a memory. Thus, the present invention allows users to easily release the security operation without compromising the level of security. Furthermore, the present invention prevents the audio equipment from being placed in an unlockable condition due to careless operation of users. | 95,649 |
[0001] The present application is a continuation of and claims the benefit of priority to U.S. application Ser. No. 12/555,305, filed Sep. 8, 2009, the entire contents of which are incorporated herein by reference. U.S. application Ser. No. 12/555,305 is a division of and claims the benefit of priority from U.S. application Ser. No. 11/250,531, filed Oct. 17, 2005, now U.S. Pat. No. 7,626,829, issued on Dec. 1, 2009, which is based upon and claims the benefit of priority from prior Japanese Application No. 2004-312791, filed Oct. 27, 2004.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a multilayer printed wiring board in which electronic components, semiconductor device and the like are mounted on the front face of a board thereof and a manufacturing method thereof and more particularly a multilayer printed wiring board preferably used for portable telephone, portable electronic appliance, electronic package and the like and a manufacturing method thereof.
[0004] 2. Description of the Related Art
[0005] A unit of the circuit board is formed by drilling via holes in an insulation hard base material having a conductive circuit on at least one face and then forming conductive layer in their openings with metallic paste or plating. A multilayer circuit board (multilayer printed wiring board) can be obtained by preparing two or more pieces of these circuit boards and bonding those boards successively or collectively such that they are overlaid into multi-layers. At this time, because a via hole or a land of the via hole of one circuit board is connected to a conductive circuit or a land of the other circuit board, these two circuit boards are electrically connected. In other region in which no electrical connection is performed, circuit boards are fitted to each other with an adhesive layer composed of thermoplastic resin or prepreg. As a conventional art relating to these, Japanese Patent Application Laid-Open No. 10-13028 can be mentioned.
[0006] A solder resist layer for protecting the conductive circuit is formed on the front face of the board or a general printed wiring board and solder pads are formed by opening part of the solder resist layer. By exposing the conductive circuit through that opening, a corrosion resistant layer such as nickel-gold is formed on its front layer. The corrosion-resistant layer is formed on all the solder pads and solder is formed on a conductive circuit covered with the corrosion-resistant layer and then an electronic component is mounted thereon.
[0007] In case of portable electronic appliances such as portable telephone, digital camera in recent years, with intensified desires for higher function and higher density and reduction in size of components to be mounted, the wiring density (line/space) in a mounting board or the size of the solder pad has been reduced so as to correspond to such desires for higher density of the components. On the formed board, solder pads of an electronic component (passive component such as semiconductor, capacitor, resistor, inductor), display devices such as liquid crystal display and digital display, operation devices such as key pad and switch, and external terminals of USB, ear phone and the like are mixed and these components are mounted on the solder pad via solder. Another solder pad allows an electronic appliance to be operated by making such an operation device as a switch into contact with the pad.
[0008] In case of a package board in which an IC chip is mounted on a printed wiring board as a bare chip as well, with intensified desire for higher function, higher density and enhanced reduction in size of a component to be mounted, desires for higher density of components have been met by decreasing wiring density (line/space) or decreasing the solder pad. The size of the board has been desired to be of chip size package (CSP) which is similar to the size of the IC chip. As a result, the package mounting region when it is mounted on a mother board decreases so that the mounting region for other components is obtained thereby making it possible to obtain a higher density mounting board. Further, by loading such an electronic component as capacitor and resistor on the package board, the high frequency of the IC chip can be met so as to obtain the function and performance of the package board.
[0009] Further, by mixing the IC chip and electronic components on a same package board, high frequency and high functional properties are obtained so as to exert the function and performance of the package board effectively.
[0010] An object of the present invention is to provide a multiplayer printed wiring board and a manufacturing method thereof, which capable of obtaining functionality and securing electric connectivity.
[0011] A multilayer printed wiring board in which a conductive circuit is formed on the front face thereof; solder-resist layer covering the conductive circuit is formed; a plurality of solder pads is formed through a plurality of openings in the solder resist which exposes part of the conductive circuit; and a corrosion resistant layer is formed on the front face of the conductive circuit, wherein
a corrosion resistant layer formation pad in which the corrosion resistant layer is formed and a corrosion resistant layer non-formation pad in which no corrosion resistant layer is formed coexist as said solder pad.
[0013] A multilayer printed wiring board in which interlayer connection is achieved through a via hole; at least two layers are overlaid with the via hole filled with a conductive layer; a solder resistant layer is formed on the front face; a plurality of solder pads is formed through a plurality of openings in the solder resist which expose part of the conductive circuit; and corrosion resistant layer is formed on the front face of the conductive circuit, wherein
the corrosion resistant layer formation pad in which corrosion resistant layer is formed and corrosion resistant layer non-formation pad in which no corrosion resistant layer is formed coexist as said solder pad.
[0015] The multilayer printed wiring board including a portion in which a corrosion resistant layer is formed and a portion in which no corrosion resistant layer is formed mixedly in its conductive layer exposed on the front face thereof can obtain reliability more easily than a conventional multilayer printed wiring board in which the corrosion resistant layer is formed on all conductive portions exposed on the front face. When an IC chip is installed or under heat cycle condition or under high temperature at high humidity, its board is elongated/contracted due to an influence of temperature. Because the surface of the board is under the same condition in the conventional multilayer printed wiring board in which the corrosion resistant layer is formed on all conductive portions exposed on the front face, stress generated by elongation/contraction is transmitted easily. Thus, the stress is difficult to buffer. However, in the multilayer printed wiring board having solder pads in which the corrosion resistant layer is formed partially, the generated stress is difficult to transmit. As a consequence, the stress is easy to buffer. For the reason, the multilayer printed wiring board of the present invention can obtain reliability more easily for a long term as compared to the conventional printed wiring board.
[0016] Because stress is buffered more as compared to the conventional printed wiring board in evaluating its electric connectivity and reliability upon drop test, the degree of deterioration decreases. As a result, reliability can be obtained more easily.
[0017] Because stress is buffered according to the present invention, warping is more difficult to generate in the multilayer printed wiring board, so that flatness of the surface of the board is obtained. Therefore, in a package board in which an IC chip is mounted as a bare chip, connectivity with the IC chip and connectivity with an external board are easy to obtain. Further, in a package board in which the IC chip and an electronic component such as a capacitor are mounted mixedly on the front face, connectivity between the IC chip and the electronic component can be obtained easily.
[0018] In a portion in which the corrosion resistant layer is formed, stiffness of the board is obtained more than a portion in which no corrosion resistant layer is formed. Because stiffness is obtained, fault of the printed wiring board like the warping of the board can be suppressed and when a component is mounted, contact failure or non-connection is difficult to generate between a conductive portion of the solder pad and an external terminal of any component. Because any mounting component is disposed on the corrosion resistant layer having stiffness, it is stabilized. Further, because an operation component such as a key pad makes contact with a land portion in which the corrosion resistant layer is formed, contact failure is difficult to occur despite repeated contacts.
[0019] Conversely, the portion in which no corrosion resistant layer is formed is more flexible than a portion in which the corrosion resistant layer is formed. Because of the flexibility, stress generated due to elongation/contraction is buffered and reliability against fault such as crack in the conductive circuit, the solder and insulation layer is easier to obtain than the conventional printed wiring board. Even if an impact is received from outside, a portion in which no corrosion resistant layer is formed can buffer that impact. Thus, any mounted component turn unlikely to receive the impact, so that faults such as drop of component become unlikely to occur.
[0020] On heating process at the time of manufacturing of the printed wiring board by hardening or reflow, the printed wiring board accompanies elongation/contraction due to heat (as an example, elongated as temperature rises and contracted when it returns from a high temperature to the normal temperature) and the portion in which no corrosion resistant layer is formed more unlikely undergoes a fault such as crack in a conductive circuit or the insulation layer as compared to the portion in which the corrosion resistant layer is formed. A fault such as crack in the solder layer is more difficult to occur. The reason is estimated to be that with elongation/contraction, the generated stress is buffered or the generated stress is more difficult to concentrate locally so that a fault such as crack is more difficult to occur. The same inclination was seen in the size (meaning vertical and horizontal sizes), thickness, quantity of layers, and material of a printed board.
[0021] The area of the portion in which the corrosion resistant layer is formed is desired to be larger than the portion in which no corrosion resistant layer is formed. The reason is that the stiffness of the board itself is easier to obtain if the area of the portion in which the corrosion resistant layer is formed is increased.
[0022] The corrosion resistant layer refers to a layer composed of one or more layers with one or more metals selected from gold, silver, platinum and the like or a layer composed of one or more layers each in which noble metals and other metals are combined. More specifically, nickel-gold, nickel-silver, nickel-platinum, gold (single layer), silver (single layer), nickel-palladium-gold, nickel-palladium-silver and the like can be mentioned.
[0023] The conductive circuit exposed from the solder pad portion may be a flat circuit, a circuit having a concavity, a circuit having a protrusion, a circuit having a roughened layer on its front face or the like.
[0024] In a condition in which such a printed wiring board is incorporated in a casing of a portable electronic appliance, a plurality of startup and driving components like semiconductor component such as MPU, capacitor and resistor, display devices such as a liquid crystal display and a digital display, an operation device such as a key pad, a switch and an external terminals such as USB, ear phone are mounted, thereby executing a role of the electronic appliance. These electronic appliances are intended to be carried with and it is supposed that it may be dropped on the ground.
[0025] The present invention can be applied to a printed wiring board in which interlayer connection is achieved through via holes, a board manufactured according to a subtractive method, a board manufactured according to an additive method and other various type printed wiring boards. Additionally, it is applicable to a board manufactured according to a conformal processing method.
[0026] The solder pad in this case includes not only a conductive circuit exposed from an opening in the solder-resist layer but also a dummy conductive layer not electrically connected, an alignment mark, a conductive layer formed to recognize a product and a terminal conductive layer for switch.
[0027] The solder pad in which the corrosion resistant layer is formed is desired to be an external terminal mainly. As a result, in the portion in which the corrosion resistant layer is formed, stiffness of the board is obtained more as compared to the portion in which no corrosion resistant layer is formed. Because stiffness is obtained, a fault of the printed wiring board such as warping of a board can be suppressed and if an external terminal is mounted, contact failure or non connection is unlikely to occur between a conductive portion of the solder pad and an external terminal of a component. Further, because the external terminal is disposed on a pad in which the corrosion resistant layer is formed, its installation is stabilized. In case of an operation component having a movable contact point which is an external terminal, like a key pad, its strength is intensified by the stiffness of that pad portion to allow repeated contact to the solder pad. Contact failure is difficult to be induced even if such an external terminal contacts repeatedly.
[0028] The solder pad in which no corrosion resistant layer is formed is desired to be an electronic component mounting terminal.
[0029] The solder pad portion in which no corrosion resistant layer is formed is more flexible than the portion in which the corrosion resistant layer is formed. When an impact is received from outside, the portion in which no corrosion resistant layer is formed can buffer that impact because it has flexibility. When an impact is received from outside due to the solder pad in which no corrosion resistant layer is formed is used at an electronic component mounting terminal, removal is difficult to occur between a conductive circuit exposed from the solder pad and an electronic component. Particularly, because the impact is buffered by the solder layer for joining them as well, crack is unlikely to occur in the solder layer so that removal is difficult to occur.
[0030] Because connectivity of the component is obtained as a result, electric connectivity or functionality as a product is not lowered and the reliability is no lower than the conventional printed wiring board. The electronic component for use at an electronic component mounting terminal includes an active component such as semiconductor and a passive component such as a capacitor, a resistor and an inductor.
[0031] The solder pad in which the corrosion resistant layer is formed is desired to be a connection pad to which the IC chip is to be connected as a bare chip mainly. Particularly, it is desired to be a wire-bonding pad or a connection solder pad for mounting the IC chip by flip chip bonding.
[0032] Because the connecting pad for the IC chip in which the corrosion resistant layer is formed is formed in a connecting region with the IC chip, stiffness of a board is obtained. Because stiffness is obtained, any fault of the printed wiring board such as warping of its board can be suppressed and even if any component is mounted, contact failure or no connection is unlikely to occur between the conductive portion of the solder pad and the external terminal of a component.
[0033] In wire bonding, formation of the corrosion resistant layer is desirable to add bonding resistance of the pad portion and metal junction. Further, because flatness of a bonding pad is held by the corrosion resistant layer, any fault is unlikely to occur at the time of bonding. Because flatness of the bonding pad is obtained, connectivity and reliability are obtained.
[0034] By forming the corrosion resistant layer upon installing the IC chip as a bare chip by flip chip bonding, the configuration and the quantity of solder bumps or metal bumps for IC chip connection formed on the pad are stabilized, thereby stabilizing connection at the time of reflow. Additionally, connectivity and reliability are obtained.
[0035] The solder pad in which no corrosion resistant layer is formed is desired to be an electronic component mounting terminal.
[0036] Conversely, the portion in which no corrosion resistant is formed is more flexible than the portion in which the corrosion resistant layer is formed. Because of the flexibility, stress generated due to elongation/contraction by heat is buffered and reliability against a fault such as crack in the conductive circuit or the insulation layer is kept for a longer term than the conventional printed wiring board. When an impact is received from outside, the portion in which no corrosion resistant layer is formed can buffer that impact. Thus, any mounted component becomes unlikely to receive the impact, so that a fault such as drop of component becomes unlikely to occur.
[0037] If a solder pad for IC chip connection and a solder pad for electronic component connection are formed on a same face of a package board, it is desirable that corrosion resistant layer is formed on the solder pad for IC chip connection while no corrosion resistant layer is formed on the solder pad for electronic component connection. As a result, if warping of a board is suppressed, an influence of the impact from outside can be buffered as compared with the conventional package board. Thus, connection with the IC chip or the electronic component mounted on the front face of the package board is obtained to protect connectivity and reliability from dropping.
[0038] An external terminal (for example, pin terminal as PGA or ball terminal as BGA) for connecting to an external board is disposed on the package board and in this case, it is desirable that no corrosion resistant layer is formed on the solder pad of that external connecting terminal. As a consequence, stress such as thermal stress generated when the external terminal is installed is buffered so that generation of a fault such as crack in the conductive material of solder for connection is suppressed, thereby obtaining connection between the connecting terminal and the board. Further, connectivity with the external board and reliability about that are easy to obtain.
[0039] The external terminals of the present invention may be disposed on a same plane as the IC chip to be mounted or on an opposite face side to the IC chip. In this case, it is permissible to dispose a region in which corrosion resistant layer is formed and a region in which no corrosion resistant layer is formed on the same plane or dispose the region in which the corrosion resistant layer is formed and the area in which no corrosion resistant layer is formed each on opposite side face. Depending on a case, it is permissible to dispose these regions mixedly.
[0040] It is desirable to provide an organic solderability preservative (OSP) (pre-flux) layer on a solder pad in which no corrosion resistant layer is formed. As a result, oxidation and the like of the conductive circuit and conductive layer is prevented until solder is installed. When solder is installed, the OSP layer is removed thereby not hampering electric connectivity. Other covering layer than the OSP layer may be applied. As an example of the OSP layer, it is permissible to use substances composed of mainly imidazole compound (for example, alkyl benz-imidazol, benz-imidazol). Metallic ion (for example, copper ion, silver ion, nickel) or organic acid may be contained. By dipping a printed wiring board whose solder pads are exposed in this solution kept between the normal temperature and heating temperature (for example, 80° C.), an organic film is applied on a copper circuit exposed from the solder pads. Solderability is obtained with this organic film. Other organic film may be used as long as it is formed on a conductor and can be removed by heating.
[0041] A manufacturing method of a multilayer printed wiring board in which a solder-resist layer covering the conductive circuit on the front face thereof is formed; a plurality of solder pads is formed through a plurality of openings in the solder resist which expose part of the conductive circuit; and a corrosion resistant layer is formed on the front face of the conductive circuit, comprising at least steps (a) to (e):
step (a) of forming a solder resist on the front face of printed wiring having a conductive circuit; step (b) of forming a solder pads by exposing/developing the solder resist or an opening with laser; step (c) of forming a mask layer for covering the solder pad on the solder resist layer in which the solder pads are formed; step (d) of forming a corrosion resistant layer on the solder pads in a non-formation portion of said mask layer; and step (e) of obtaining a plurality of solder pads including a corrosion resistant layer formation solder pads in which corrosion resistant layer is formed and corrosion resistant layer non-formation solder pads in which no corrosion resistant layer is formed mixedly by removing the mask resist layer.
[0047] According to the above-described manufacturing method, a multilayer printed wiring board in which a portion including the corrosion resistant layer and a portion including no corrosion resistant layer coexist in a conductive layer whose face is exposed can be manufactured. According to the printed wiring board obtained by the manufacturing method of the invention, its reliability is easier to obtain as compared with the conventional multilayer printed wiring board in which the corrosion resistant layer is formed on all the conductive portion exposed on the face.
[0048] Because stress is buffered, which is testified by evaluating the electric connectivity and reliability through a drop test, the degree of deterioration can be reduced. As a result, the reliability is hard to drop.
[0049] In the process (C), the solder pad to be covered with mask layer is desired to be an electronic component mounting pad or an external terminal connecting pad.
[0050] By covering with the mask layer, a corrosion resistant layer non-formation solder pad portion in which no corrosion resistant layer is formed can be formed. That corrosion resistant layer non-formation solder pad portion is more flexible than a portion in which the corrosion resistant layer is formed. When an impact is received from outside, the portion in which no corrosion resistant layer is formed can buffer that impact because it has flexibility. By using the solder pad in which no corrosion resistant layer is formed for an electronic component mounting terminal, an electronic component is protected from dropping from a conductive circuit exposed from the solder pad when an impact is received from outside.
[0051] Particularly, because the impact is buffered by the solder layer for joining those, a crack in the solder layer is hard to occur so that the electronic component or the external terminal is protected from dropping.
[0052] As a consequence, connectivity with a component or external terminal is obtained, thus, electric connectivity and functionality as a product are obtained and reliability is easy obtained.
[0053] The mask layer can cover the solder pad in which no corrosion resistant layer is formed, through exposure/development or drilling by laser. That is, a portion in which the mask layer is to be formed and a portion in which the mask layer is not to be formed are formed on the front face of a board covered with the solder resist layer and a plating film is applied to the mask layer non-formation portion. The mask layer is formed by coating with resin whose viscosity is adjusted preliminarily or bonding dry film. The mask layer is formed in a region in which no corrosion resistant layer is formed and no corrosion resistant layer is formed on a solder pad located under the mask layer. An opening is made in the mask layer by exposure/development or by laser in other solder pad region.
[0054] As a consequence, the mask layer non-formation portion is formed on the solder resist layer and corrosion resistant layer is formed on the solder pad in the non-formation area. As a consequence, the portion in which the corrosion resistant layer is formed and the portion in which no corrosion resistant layer is formed can be formed on the solder pad.
[0055] After the process (e), it is permissible to form the OSP layer on the solder pad in which no corrosion resistant layer is formed.
[0056] It is desirable to provide organic solderability preservative (OSP) (pre-flux) layer on the solder pad in which no corrosion resistant layer is formed. As a consequence, oxidation and the like of the conductive circuit and the conductive layer is inhibited until the solder is installed. Then, when the solder is installed, the OSP layer is removed not to hamper electric connectivity.
[0057] The above-described manufacturing method enables the multilayer printed wiring board for package board to be manufactured. As an example, the corrosion resistant layer is formed on a solder pad for mounting a bare chip for the IC chip and the corrosion resistant layer is not formed on a solder pad for an electronic component such as a capacitor. These portions may be provided on a same face.
[0058] Thus, the mask layer is applied to the solder pad for electronic component mainly. As a consequence, no corrosion resistant layer is formed on that given solder pad.
[0059] Each of the following processes will be described in detail. Process (a) for forming solder resist on the front layer of a printed wiring board having a conductive circuit and process (b) for forming solder pad by exposing/developing on the solder resist or drilling by laser will be described. The solder resist layer is formed on a printed wiring board in which a dummy conductive layer not connected electrically with a land containing a conductive circuit or a conductive layer for recognizing an alignment mark, product is formed on a single face or both faces. If it is needed, blackening or roughening may be executed on the conductive circuit and the conductive layer. The printed wiring board mentioned here refers to a printed wiring board in which interlayer connection is achieved through via holes, a board manufactured according to the subtractive method, a board manufactured according to the additive method and other various type printed wiring boards.
[0060] Solder resist is formed by applying resin whose viscosity is adjusted preliminary or bonding dry-film-like film or pressing that film by heat. The thickness of the formed solder resist is 10-50 μm and the thickness of the solder resist after completely hardened is 5-50 μm. As the solder resist, heat hardening resin, thermoplastic resin, photopolymerizing polymer, resin produced by converting part of heat hardening resin to (meta) acrylic and compound of these resins are used and of them, it is desirable to use epoxy resin, polyimide resin, phenol resin, polyolefin resin, phenoxy resin and the like. If it is needed, formed solder resist layer may be dried at 80 to 100° C. As a consequence, the solder resist layer is turned to semi-hardened (B stage) state.
[0061] After that, with a mask on which solder pads are drawn placed on the solder resist layer, ultraviolet ray or the like is irradiated and openings of the solder pads are made in the solder resist layer by development with chemical such as alkali solution. Alternatively, the openings of the solder pads are made in the solder resist layer by laser.
[0062] As laser in use for drilling the openings at this time, carbon dioxide gas laser, excimer laser, YAG laser and the like may be used. To provide the solder pads with the openings by carbon dioxide gas laser, it is desirable that its pulse energy is 0.5 to 100 mJ, the pulse width is 1 to 100 μ, the pulse interval is 0.5 ms or more and the frequency is 1000 to 6000 Hz. Further, the via hole may be formed by abrasion. After the openings are made with laser beam, it is permissible to carry out a desmear treatment by physical treatment such as chemical treatment with acid or oxidizing agent, plasma treatment, corona treatment with oxygen, nitrogen or the like.
[0063] After that, by hardening at 100 to 200° C. for at least 30 minutes, the solder resist layer is hardened completely. The solder pad of this case includes not only a conductive circuit but also a dummy conductive layer not connected electrically, an alignment mark and a conductive layer formed for recognizing a product.
[0064] As a result, a printed wiring board having solder resist with openings for the solder pads on the conductive circuit and conductive layer can be obtained.
[0065] (c) The process for forming the mask layer for covering the solder pads on the solder resist layer on which the solder pads are formed will be described. The mask layer is formed on a printed wiring board in which the solder pads are formed in the solder resist layer.
[0066] The mask layer is formed by applying resin whose viscosity is adjusted preliminarily or bonding dry-film like film or pressing that film by heat. The thickness of the mask layer is 5 to 30 μm. As the mask, heat hardening resin, thermoplastic resin, photopolymerizing polymer, resin produced by converting part of heat hardening resin to (meta) acrylic and compound of these resins are used, and of them, it is desirable to use epoxy resin, polyimide resin, phenol resin, polyolefin resin, phenoxy resin and the like. If it is needed, formed mask layer may be dried at 80 to 100° C. As a consequence, the mask layer may be turned to semi-hardened (B stage) state. A film processed in this B-stage may be bonded. Depending on the case, this may be done by exposure to draw directly.
[0067] After that, with a mask on which a non-formation region of the solder pads is drawn placed on the mask layer, ultraviolet ray is irradiated and openings of the non-formation region of the corrosion resistant layer are made by development with chemical such as alkali solution or by irradiation with laser beam. As a result, a mask non-formation portion and a mask formation portion are formed.
[0068] As laser in use for providing the mask layer with openings at this time, carbon dioxide gas laser, excimer laser, YAG laser and the like may be used. To provide the mask layer with the openings using carbon dioxide gas laser, it is desirable that its pulse energy is 0.5 to 100 ml, the pulse width is 1 to 100 μs, the pulse interval is 0.5 ms or more and the frequency is 1000 to 6000 Hz. Further, the via hole may be formed by abrasion. After the openings are made with laser beam, it is permissible to carry out desmear treatment by physical treatment such as chemical treatment with acid or oxidizing agent, plasma treatment, corona treatment with oxygen, nitrogen or the like. The corrosion resistant layer is formed on the solder pad in the mask layer non-formation region.
[0069] (d) The process of forming the corrosion resistant layer on the solder pad in the mask layer non-formation portion and process (e) of obtaining a plurality of solder pads including solder pads in which the corrosion resistant layer is formed and solder pads in which no corrosion resistant layer is formed mixedly by peeling the mask resist layer will be described.
[0070] The corrosion resistant layer is formed in the mask layer non-formation portion of the solder resist layer. In this case, the corrosion resistant layer refers to a layer composed of one or more layers with one or more metals selected from gold, silver, platinum, and noble metal. More specifically, nickel-gold, nickel-silver, nickel-platinum, gold (single layer), silver (single layer), nickel-palladium-gold, nickel-palladium-silver and the like can be mentioned.
[0071] These corrosion resistant layers may be formed by plating (electrolytic plating, electroless plating, displacement plating.) Alternatively, it may be formed by vapor deposition like sputtering. The corrosion resistant layer may be formed of a single layer or two or more layers.
[0072] Consequently, the corrosion resistant layer is formed on the solder pad corresponding to the mask layer non-formation portion. After that, a printed wiring board including the corrosion resistant layer formation solder pads in which the corrosion resistant layer is formed and the corrosion resistant layer non-formation solder pads in which no corrosion resistant layer is formed mixedly can be obtained by peeling the mask layer with alikali solution and likes.
[0073] It is desirable to provide an organic solderability preservative (OSP) (pre-flux) layer on the solder pad in which no corrosion resistant layer is formed by printing or spraying and likes. As a consequence, oxidation of the conductive circuit and the conductive layer can be inhibited until the solder is installed. Then, when the solder is installed, the OSP layer is removed not to hamper electric connectivity.
[0074] After that, by disposing solders of Sn—Pb, Sn—Ag—Cu or the like on each pad by printing, a printed wiring board in which solder layer is formed in the form of pads, constituted of conductive circuits (including lands) is obtained. Electronic components such as MPU, capacitor and resistor, display devices such as the liquid crystal display and the digital display, the operation device such as the key pad, the switch and the external terminals of USB, the ear phone and other external terminal are mounted on this board.
[0075] More desirably, the solder pad in which no corrosion resistant layer is formed is used as an electronic component mounting terminal and the solder pad in which the corrosion resistant layer is formed is used for an external terminal.
[0076] With this structure, reliability is more unlikely to drop as compared to a conventional multilayer printed wiring board in which the corrosion resistant layer is formed on all conductive portions exposed on the front face.
[0077] Particularly, as evident from evaluation of electric connectivity and reliability upon drop test, the degree of deterioration can be reduced as compared to the conventional printed wiring board and as a consequence, reliability for a long term is easy to maintain thereby the reliability is unlikely to drop.
[0078] Hereinafter an example of the manufacturing method of the multilayer printed wiring board of the present invention will be described with reference to the accompanying drawings.
[0079] (1) For manufacturing the multilayer printed wiring board of the present invention, as a circuit board serving as a basic unit constituting it, an insulation base material 30 whose one face or both faces are equipped with copper foil 32 is used as its starting material ( FIG. 1(A) ).
[0080] Although as this insulation base material for example, hard lamination base material selected from glass fabric epoxy resin base material, glass fabric bismaleimide triazine base material, glass fabric polyphenylene ether resin base material, aramide nonwoven fabric-epoxy resin base material, aramide unwoven-polyimde resin base material may be used, the glass fabric epoxy resin base material is the most desirable.
[0081] Preferably the thickness of the insulation base material is 20-600 μm. The reason is that if the thickness is less than 20 μm, its strength drops so that it is difficult to handle and at the same time, reliability to the electric insulation property drops, so that formation of the via hole may be difficult. Conversely, if the thickness is over 600 μm, formation of a fine via hole or depending on a case, filling with conductive paste is difficult and at the same time, the board itself turns thick.
[0082] Preferably, the thickness of the copper foil is 5-18 μm. To form the via holes in a circuit board with laser beam, a direct laser method of making the via hole in the copper foil and the insulation base material at the same time and the conformal method of removing a portion corresponding to the via hole in the copper foil by etching are available and any one may be used.
[0083] If the thickness of the copper foil is less than 5 μm, an end face of the via hole in the copper foil can be deformed when an opening for formation of the via hole is formed in the insulation base material by using a laser processing described later, so that a conductive circuit is difficult to form. If the thickness of the copper foil is over 18 μm, a conductive circuit pattern of fine lines is difficult to form by etching.
[0084] The copper foil 32 may be adjusted in thickness by half etching ( FIG. 1(B) ). In this case, as the copper foil 32 , the one having a thickness larger than the above mentioned value (5 to 18 μm) is used. After half etching, the thickness of the copper foil is adjusted to 5 to 18 μm. In case of double sided copper clad lamination, the thicknesses of both faces are permitted to be different if the thicknesses of the copper foil are in the above-mentioned range. As a consequence, the strength can be intensified thereby executing following steps smoothly.
[0085] If the conductive circuit is formed on a single face by etching, it is easy to form.
[0086] As the insulation base material and the copper foil, preferably, a single sided or double sided copper clad lamination obtained by overlaying prepreg as B-stage produced by impregnating glass fabric with epoxy resin and copper foil and pressing them with heat is used. The reason is that the position of wiring pattern or via hole is not deflected during handling after the copper foil is etched and its positional accuracy is excellent.
[0087] (2) Next, an opening 34 is formed so that it reaches from the front face of the insulation base material 30 to the copper foil (or conductive circuit pattern) 32 on the rear face by irradiating the front face of the insulation base material 30 with the copper foil 32 with carbon dioxide gas laser ( FIG. 1(C) .
[0088] This laser processing is carried out with a pulse oscillation type carbon dioxide gas laser processing unit and preferably, its processing condition is that pulse energy is 0.5 to 100 mJ, pulse width is 1 to 100 pulse interval is 0.5 ms or more and the quantity of shots is in a range of 1 to 50.
[0089] The diameter of a via formation opening 34 which can be formed under such condition is preferred to be 50 to 250 μm.
[0090] (3) A desmear treatment is carried out to remove residual resin left on a side face and bottom of an opening formed in the step (2).
[0091] This desmear treatment is carried out according to wet processing such as chemical treatment with acid or oxidizing agent (for example, chromic acid, permanganic acid), or dry processing such as an oxide-plasma discharge treatment, a corona discharge treatment, an ultraviolet laser treatment and an excimer laser treatment. Such a desmear treatment is selected corresponding to the quantity of smear estimated to be left depending on the type and thickness of insulation base material, the diameter of opening for the via hole, laser condition and the like.
[0092] (4) Electrolytic copper plating treatment, the copper foil 32 as lead plating, is carried out to the copper foil face of a board undergoing the desmear treatment to fill the openings with electrolytic copper plating 36 thereby producing via holes 46 filled like a field. ( FIG. 1 (D))
[0093] Depending on a case, electrolytic copper plating swollen on the top of the via hole opening on the board may be flattened by removing by belt sander polishing, buffing, etching or the like after the electrolytic copper plating treatment is finished.
[0094] Further, electrolytic plating may be formed through electroless plating. In this case, as electroless plating film, copper, nickel, silver or the like may be used.
[0095] (5) A resist layer 38 is formed on the electrolytic copper plating 36 ( FIG. 2(A) ). This resist layer may be formed by coating or bonding film-like material. An etching resist layer is formed by exposure/development with a mask on which a circuit is drawn preliminary placed on this resist film and a metallic layer of an etching resist non-formation portion is etched to form conductive circuit patterns 44 and 42 including the conductive circuit and the land ( FIG. 2(B) ).
[0096] As this etching solution, preferably, at least an aqueous solution selected from sulfuric acid-hydrogen peroxide, persulfate, copper (II) chloride and ferric (II) chloride is used. As pre-treatment for forming a conductive circuit by etching the copper foil, the thickness of the copper foil may be adjusted by etching the entire surface thereof to facilitate formation of a fine pattern. Although the inside diameter of the land as part of the conductive circuit is substantially the same as the diameter of the via hole, preferably, the outside diameter is in a range of 50 to 250 μm.
[0097] The single sided circuit board 30 manufactured through the steps (1) to (5) is a unit of circuit board having the copper foil as a conductive layer on one surface of the insulation base material and filled via holes in openings reaching from the other face to the copper foil. A multilayer circuit board is formed by overlaying a plurality of the circuit boards. Upon this overlaying, the multilayer circuit board may be formed by pressing all overlaid circuit boards collectively with heat. Alternatively, the multilayer circuit board may be formed by overlaying at least one circuit board successively into a multilayer structure. As the circuit board, the double sided circuit board may be used or the single sided circuit board may be used or both of them may be used mixedly.
[0098] (6) A plurality of the circuit boards is overlaid ( FIG. 3(A) ) and pressed with heat under a condition that heating temperature is 150 to 250° C. and pressure is 1 to 10 MPa to integrate into a multilayer structure ( FIG. 3(B) ). Preferably, this hot press is carried out under a reduced pressure. As a consequence, adhesion of the boards is obtained.
[0099] Further by etching the copper foil of a single sided circuit board of the topmost layer of the circuit boards integrated in the (6) and the copper foil of a single sided circuit board on the outermost side, conductive circuits (including via holes land) may be formed. In this etching process, after photosensitive dry film resist is bonded to the surface of the overlaid and pressed copper foil, the conductive circuits including the via hole land are formed by forming etching resist through exposure and development according to a predetermined circuit pattern and then etching the metallic layer of an etching resist non-formation portion.
[0100] (7) Next, a solder resist layer 90 is formed each on the surface of a circuit board on the outermost side ( FIG. 4(A) ). In this case, solder resist compound is applied to the entire outside surface of the circuit board and its coating film is dried. Then, this film is exposed to light and developed with a photo mask film on which openings for the solder pads are drawn placed on this coating film, so that conductive pad portions located just above the via holes of the conductive circuit are exposed outside to form a solder pad openings 90 a. In this case, the openings may be formed by bonding a dry-film like solder resist layer and exposing/developing or using laser.
[0101] (8) A mask layer 50 a is formed by coating or bonding a film on a board in which solder pads are opened in the solder resist layer 90 . Then, a non-formation portion of the mask layer 50 is formed by exposure and development with an exposure mask 50 on which a formation portion 52 a of the mask layer is drawn placed on the mask layer 50 a ( FIG. 4(C) ). As a consequence, the solder pads 60 B formed on the solder resist layer 60 are covered with the mask layer 50 .
[0102] The corrosion resistant layer is formed nickel 54 -gold 56 on the solder pads 60 A exposed from the non-formation portion of the mask layer 20 ( FIGS. 5(A) and (B 1 )). At this time, the thickness of the nickel layer 54 is desired to be 1 to 7 μm and the thickness of the gold layer 56 is desired to be 0.01 to 0.1 μm. Additionally, it is permissible to form the corrosion resistant layer of nickel-palladium-gold, gold (single layer), silver (single layer) or the like.
[0103] After the corrosion resistant layer is formed, the mask layer 50 is broken away. As a consequence, the corrosion resistant layer formation solder pads 60 A in which the corrosion resistant layer is formed and the corrosion resistant layer non-formation solder pads 60 B in which no corrosion resistant layer is formed come to exist on the printed wiring board ( FIG. 5(C) ).
[0104] In case of a portable electronic appliance, the solder pads exposed from the solder resist layer, the portion in which the corrosion resistant layer is formed is used for mainly an external terminal and the corrosion resistant layer non-formation portion is used for mainly an electronic component mounting terminal.
[0105] In case of a package board, the solder pads exposed from the solder resist layer, the portion in which the corrosion resistant layer is formed is used for mainly the terminal of an IC chip mounted as a bare chip and the corrosion resistant layer non-formation portion is used for mainly the electronic componet mounting terminal or as the pad for the external terminal.
[0106] (9) By supplying a solder body to the solder pad portions exposed just above the via hole from an opening in the solder resist obtained in the (8), solder bumps 96 U, 96 D are formed by melting/solidification of this solder body ( FIG. 6 ). Alternatively, by connecting a conductive ball or a conductive pin to the pad portion with a conductive adhesive agent or a solder layer, the multilayer circuit board is formed. Additionally, a capacitor, resistor or the like may be mounted on the formed solder layer. Further, an external terminal such as a key pad may be mounted on the solder layer.
[0107] As a supply method for the solder body and the solder layer, a solder transfer method or a print method may be used.
[0108] According to the solder transfer method, a solder foil is bonded to prepreg and this solder foil is etched leaving only portions corresponding to the opening portions to form a solder pattern as the solder carrier film. After flux is applied to the solder resist opening portion of the board, this solder carrier film is overlaid so that the solder pattern makes contact with the pads and transferred by heating.
[0109] On the other hand, according to the print method, a print mask (metal mask) provided with openings at portions corresponding to the pads is placed on a board and solder paste is printed and treated with heat. As solder for forming such a solder bump, Sn/Ag solder, Sn/In solder, Sn/Zn solder, Sn/Bi solder and the like may be used.
[0110] Consequently, a printed wiring board for a portable electronic appliance is obtained.
[0111] If a bare chip is mounted for the package board by flip chip bonding, the external terminals are disposed on a same plane as the IC chip or on a face on an opposite side to the IC chip.
[0112] If the IC chip, an electronic component and external terminals are provided on the package board by solder, the melting point of solder to be connected to the IC chip is desired to be equal to or lower than the melting point of the solder to be connected to the external terminal. As a consequence, connectivity between a connection terminal and board is obtained easily.
[0113] If the bare chip is mounted for the package board by wire bonding, the external terminals are disposed on a same plane as the IC chip or on a face on an opposite side to the IC chip.
[0114] In addition to the manufacturing method described above, the subtractive method, a semi additive method, a full additive method or a combination of these two or more methods can be applied for manufacturing the board. Although a board having the via holes (non through hole) is represented in the drawings, a board whose interlayer connection is achieved by through holes which go through all layers of the board may be used.
BRIEF DESCRIPTION OF THE DRAWINGS
[0115] FIG. 1 is a process diagram showing a manufacturing method of a multilayer printed wiring board according to an example 1 of the present invention;
[0116] FIG. 2 is a process diagram showing the manufacturing method of the multilayer printed wiring board according to the example 1;
[0117] FIG. 3 is a process diagram showing the manufacturing method of the multilayer printed wiring board according to the example 1;
[0118] FIG. 4 is a process diagram showing the manufacturing method of the multilayer printed wiring board according to the example 1;
[0119] FIG. 5 is a process diagram showing the manufacturing method of the multilayer printed wiring board according to the example 1;
[0120] FIG. 6 is a sectional view of the multilayer printed wiring board according to the example 1;
[0121] FIG. 7 is a sectional view of the multilayer printed wiring board of FIG. 6 indicating a condition in which components are mounted;
[0122] FIG. 8 is a plan view showing a manufacturing method of the multilayer printed wiring board according to the example 1;
[0123] FIG. 9 is a plan view of the printed wiring board applied to a portable telephone of the example 1;
[0124] FIG. 10 is a table showing an evaluation result of the example 1 and a comparative example 1;
[0125] FIG. 11(A) is a perspective view of a package board according to example 2-1-1 before an IC chip is mounted, FIG. 11(B) is a sectional view taken along the line B-B of FIG. 11(A) , FIG. 11(C) is a perspective view of a package board after the IC chip is mounted and FIG. 11(D) is a sectional view taken along the line D-D of FIG. 11(C) ;
[0126] FIG. 12 (A 1 ) is a plan view of a package board according to example 2-1-1 before an IC chip is mounted, FIG. 12 (B 1 ) is a rear view thereof, FIG. 12 (A 2 ) is a plan view of the package board after the IC chip is mounted and FIG. 12 (B 2 ) is a rear view thereof;
[0127] FIG. 13 (A 1 ) is a plan view of the package board according to example 2-2-1 before the IC chip is mounted, FIG. 13 (B 1 ) is a rear view thereof, FIG. 13 (A 2 ) is a plan view of the package board after the IC chip is mounted, and FIG. 13 (B 2 ) is a rear view thereof;
[0128] FIG. 14 (A 1 ) is a plan view of a package board according to example 2-3-1 before an IC chip is mounted, FIG. 14 (B 1 ) is a rear view thereof, FIG. 14 (A 2 ) is a plan view of the package board after the IC chip is mounted and FIG. 14 (B 2 ) is a rear view thereof;
[0129] FIG. 15 (A 1 ) is a plan view of a package board according to example 2-4-1 before an IC chip is mounted, FIG. 15 (B 1 ) is a rear view thereof, FIG. 15 (A 2 ) is a plan view of the package board after the IC chip is mounted and FIG. 15 (B 2 ) is a rear view thereof;
[0130] FIG. 16 (A 1 ) is a plan view of a package board according to example 2-5-1 before an IC chip is mounted, FIG. 16 (B 1 ) is a rear view thereof, FIG. 16 (A 2 ) is a plan view of the package board after the IC chip is mounted and FIG. 16 (B 2 ) is a rear view thereof;
[0131] FIG. 17 (A 1 ) is a plan view of a package board according to example 2-6-1 before an IC chip is mounted, FIG. 17 (B 1 ) is a rear view thereof, FIG. 17 (A 2 ) is a plan view of the package board after the IC chip is mounted and FIG. 17 (B 2 ) is a rear view thereof; and
[0132] FIG. 18 is a table showing an evaluation result of the example 2 and comparative example 2.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
Example 1-1
[0133] (1) First, a double sided circuit board intended to constitute a multilayer circuit board is manufactured. This circuit board utilizes a double sided copper-clad lamination obtained by overlaying prepreg 30 as B-stage created by impregnating glass fabric with expoxy resin and copper foil 32 and pressing with heat as a starting material ( FIG. 1(A) ).
[0134] The thickness of this insulation base material was 75 μm and the thickness of the copper foil was 12 μm. It is permissible to use a copper foil thicker than 12 μm as this layered board and then adjust the thickness of the copper foil to 12 μm by etching treatment ( FIG. 1(B) ).
[0135] (2) The copper foil 32 and the insulation base material 30 were drilled by irradiating the double sided circuit board having the copper foil 32 with carbon dioxide gas laser and a via hole formation opening 34 reaching the copper foil 32 on an opposite side was formed ( FIG. 1(C) ). Further, the desmear treatment was performed within the opening by chemical treatment with permanganic acid.
[0136] To form the opening for via hole formation in this example, HITACHI VIA ENGINEERING LTD. manufactured high peak short pulse oscillation type carbon dioxide gas laser processor machine was used. Then, openings 34 with 80 μm in diameter for via hole formation were formed in glass fabric epoxy resin base material whose base material was 75 μm thick at a speed of 100 holes/second by irradiating directory to the copper foil with laser beam.
[0137] (3) Electrolytic copper plating treatment with copper foil as plating lead was carried out under a following condition on the copper foil face after the via holes were drilled in the insulation base material subjected to the desmear treatment.
[0000] [Electrolytic plating solution]
Sulfuric acid: 2.24 mol/l
Copper sulfate: 0.26 mol/l
Additive A (reaction accelerator): 10.0 ml/l
Additive B (reaction inhibitor): 10.0 ml/l
[Electrolytic plating condition]
Current density: 1 A/dm 2
Time: 65 minutes
Temperature: 22±2° C.
[0138] Formation of electrolytic copper plating film within the via hole was accelerated by the additive A and conversely, the additive B adheres to mainly the copper foil portion so as to inhibit formation of the plating film. When the via hole is filled with the electrolytic copper plating so that the height thereof turns substantially equal to the height of the copper foil, the additive B adheres thereby inhibiting the formation of the plating film like the copper foil portion. As a consequence, the opening 34 was filled with an electrolytic copper plating 36 so as to form a via hole 46 in which its via hole portion and the copper foil were flattened to the same level ( FIG. 1(D) ).
[0139] The thickness may be adjusted by etching the conductive layer comprising the copper foil and the electrolytic plating film. Depending on a case, it is permissible to adjust the thickness of the conductive layer according to the physical method of sander belt polishing and buffing.
[0140] (4) Photosensitive dry film etching resist 38 was formed on the copper foil 32 and the copper plating 36 as the insulation base material passing the aforementioned process (3) ( FIG. 2(A) ). The resist 38 was formed in the thickness of 15 to 20 μm and resist non-formation portion was formed on the copper foil through the process of the conductive circuit, the land of the via hole and exposure/development. Then, the copper plating film and the copper foil corresponding to the non-formation portion are removed by etching the resist non-formation portion with etching solution composed of hydrogen peroxide solution/sulfuric acid.
[0141] (5) After that, the resist 38 is broken away with alkali solution so as to form conductive circuits 42 and 44 and a via hole 46 ( FIG. 2(B) ). As a consequence, a circuit board in which the via hole 46 for connecting the front and rear faces exists and that via hole and the copper foil portion serving as a conductive circuit are flattened to the same level is obtained. After that, it is permissible to provide a blackened layer 44 B on the conductive circuits 42 and 44 by blackening ( FIG. 2(C) ).
[0142] With the circuit board 30 obtained through the processes (1) to (5) as a unit (FIG. 3 (A)), the boards 30 were overlaid with an adhesive material layer 48 like prepreg sandwiched therebetween and pressed with heat under a condition in which the temperature was 80 to 250° C. and the pressure was 1.0 to 5.0 kgf/cm 2 so as to form the multilayer wiring board 10 ( FIG. 3(B) ).
[0143] (10) The solder resist layer was formed on the surface of the circuit board located at the topmost layer and bottommost layer of the multilayer board 10 . The solder resist layer was formed in the thickness of 20 to 30 μm by bonding a film solder resist layer or applying varnish whose viscosity was adjusted preliminarily.
[0144] Next, drying treatment was carried out at 70° C. for 20 minutes and 100° C. for 30 minutes and then, by using soda lime glass board of 5 mm in thick on which a circular pattern (mask pattern) was drawn with a chrome layer for a solder resist opening with a side on which the chrome layer was formed fitted to the solder resist layer, ultraviolet ray of 1000 mJ/cm 2 was irradiated and then DMTG development was executed. Further, this multilayer board 10 was heat treated at 120° C. for an hour and 150° C. for three hours so as to form the solder resist layer of 20 μm in thick having an opening 90 a corresponding to a pad portion (diameter of the opening: 200 μm) ( FIG. 4(A) ). FIG. 8(A) shows a plan view of this multilayer printed wiring board 10 . FIG. 4(A) corresponds to a section taken along the line a-a in FIG. 8(A) .
[0145] Before the solder resist layer is formed, a roughened layer is provided on the surface of a circuit board located at the topmost layer and, if it is needed, the bottommost layer of the multilayer board.
[0146] (11) A dry film like mask layer is formed of photosensitive resin on the solder resist layer. The mask layer was formed in the thickness of 10 to 20 μm on the solder resist layer by bonding a film-like mask layer or applying varnish whose viscosity was adjusted preliminarily.
[0147] Next, drying treatment was carried out at 80° C. for 30 minutes and with a soda lime glass board 52 of 5 mm in thick on which a mask layer non-formation pattern (mask pattern) 52 a was drawn fitted to the mask layer 50 a, ultraviolet ray of 800 mJ/cm 2 was irradiated ( FIG. 4(B) ) and DMTG development was carried out. Further, this multilayer board was heat treated at 120° C. for an hour so as to form a mask layer formation portion whose solder pad 60 B is covered in a region in which no corrosion resistant layer is formed, and a mask layer 50 (15 μm in thick) composed of a mask layer non-formation portion whose solder pad 60 A is exposed in a region in which corrosion resistant layer is formed. FIG. 8(B) shows a plan view of this multilayer printed wiring board 10 . A section taken along the line b-b in FIG. 8(B) corresponds to FIG. 4(C) .
[0148] (12) Next, after the solder resist layer is formed, the board was dipped in electroless nickel plating solution having pH=5 composed of nickel sulfate of 6.0 g/l and sodium hypophosphite of 25 g/l for 40 minutes so as to form a nickel plating layer 54 of 4 μm in thick in the opening 90 a (solder pad 60 A) ( FIG. 5(A) ).
[0149] Further, the board was dipped in electroless gold plating solution composed of potassium gold cyanide of 1.5 g/l and citric acid of 80 g/l for 600 seconds so as to form a gold plating layer 56 of 0.05 μm in thick on the nickel plating layer 54 so that a corrosion resistant metallic layer was formed of the nickel plating layer 54 and the gold plating layer 56 ( FIG. 5(B) ). FIG. 8(C) shows a plan view of this multilayer printed wiring board 10 . A section taken along the line c-c in FIG. 8(C) corresponds to FIG. 5(B) .
[0150] As a consequence, the corrosion resistant layer was formed composed of nickel 54 -gold 56 in the solder pad 60 A corresponding to the non-formation portion of the mask layer 50 . After that, by peeling the mask layer 50 with alkali solution and the like, a multilayer printed wiring board 10 , in which the corrosion resistant layer formation solder pad 60 A including a corrosion resistant layer and the corrosion resistant non-formation solder pad 60 B including no corrosion resistant layer coexist, was obtained. An OPS layer 58 was formed in the corrosion resistant non-formation solder pad 60 B ( FIG. 5(C) ). FIG. 8(D) shows a plan view of this multilayer printed wiring board 10 . A section taken along the line d-d in FIG. 8(D) corresponds to FIG. 5(C) .
[0151] (13) Then, solder paste composed of Sn/Pb solder whose melting point T 2 was about 183° C. was printed to the solder pads 60 A and 60 B exposed through an opening in the solder resist layer covering the multilayer circuit board on the topmost layer and reflowed at 183° C., so as to form solder layers 96 U and 96 D ( FIG. 6 ).
[0152] An electronic component 82 B, mainly a capacitor and a resistor is mounted on the solder layers 96 U and 96 D on the corrosion resistant non-formation solder pad 60 B in which no corrosion resistant layer is formed and an external terminal 92 A, mainly, a key pad is mounted in a region in which the solder layers 96 U and 96 D are formed on the corrosion resistant formation solder pad 60 A ( FIG. 7 ).
[0153] FIG. 9 is a plan view of a multilayer printed wiring board for a portable telephone manufactured according to the manufacturing method of the example 1.
[0154] The solder pad 60 B on which a component is to be mounted via solder and the land 60 A, which corrosion resistant layer is formed of nickel layer-gold layer, constituting the terminal of a key pad, are provided on the opening 90 a of the solder-resist layer 90 of the multilayer printed wiring board. The land 60 A is comprised of a central portion 60 Ac and a ring portion 60 Ar located around it. A carbon pillar (conductive member) held by a holding member having plasticity is disposed above the land 60 A and when a key is operated, the carbon pillar connects electrically the central portion 60 Ac with the ring portion 60 Ar.
Example 1-2
[0155] This example is the same as the example 1-1 except that no OPS layer was formed on a solder pad in which the corrosion resistant layer of the example 1-1 is not formed.
Example 1-3
[0156] This example is the same as the example 1-1 except that corrosion resistant layer of nickel-palladium-gold was formed on the solder pad in which the corrosion resistant layer of the example 1-1 was formed.
Example 1-4
[0157] This example is the same as the example 1-1 except that corrosion resistant layer was formed of single layer gold on the solder pad in which the corrosion resistant layer of the example 1-1 was formed.
Comparative Example 1-1
[0158] In the comparative example 1-1, the corrosion resistant layer (nickel-gold) was formed on all solder pads. Other matters are the same as the example 1-1.
[0159] In a group of the example 1 and the comparative example 1, manufactured printed wiring boards were evaluated according to an item A and after the manufactured printed wiring board was accommodated into a casing, evaluation on items B and C was performed. This evaluation result is indicated in FIG. 10 .
1-A. Reliability Test
[0160] Under the heat cycle condition (130° C./3 min and 55° C./3 min as a cycle), this cycle test was repeated up to 5,000 cycles and every other 500 cycles, a test piece was left for 2 hours after the test ended and a continuity test was carried out. The number of cycles up to when circuits whose resistance change ratio exceeded ±10% exceeded 50% measured circuits were compared.
1-B. Startup Test
[0161] As for a casing equipped with power supply, whether or not the test piece was started up smoothly when it was powered was judged.
[0000] Started within two seconds after the power was turned on: ◯
Started within 10 seconds after the power was turned on: Δ
Did not start: X
1-C. Drop Test
[0162] A test piece was dropped naturally from a base fixed at a height of 1 m with its liquid crystal portion facing downward. This test was executed once, three times and five times and each time, startup test of B was carried out.
Second Embodiment
[0163] In the first embodiment described above with reference to FIGS. 1-10 , an example that the multilayer printed wiring board of the present invention was applied to the multilayer printed wiring board of a portable phone has been picked up. Contrary to this, according to the second embodiment, the printed wiring board of the present invention is applied to a package board loaded with an IC chip.
Example 2-1-1
[0164] Although the manufacturing process is the same as the example 1-1, the example 2-1-1 is used as a package board. FIG. 11(A) shows a perspective view of a package board 70 before the IC chip is mounted. FIG. 11(B) shows a sectional view taken along the line B-B of FIG. 11(A) . FIG. 11(C) shows a perspective view of the package board after the IC chip is mounted. FIG. 11(D) shows a sectional view taken along the line D-D of FIG. 11(C) . FIG. 12 (A 1 ) shows a plan view of the package board 70 before the IC chip is mounted. FIG. 12 (B 1 ) shows a rear view and FIG. 12 (A 2 ) shows a plan view of the package board 70 after the IC chip is mounted. FIG. 12 (B 2 ) shows a rear view.
[0165] As shown in FIGS. 11 (A) and 12 (A 1 ), a cavity 74 is provided in the face of the package board 70 and a bonding pads 72 extend in the cavity 74 . As shown in FIG. 11(B) , the package board 70 is produced by overlaying the boards 30 each in which the via holes 46 are formed. The corrosion resistant layer composed of the nickel layer 54 and the gold layer 56 are formed on the bonding pads 72 on the front face. The OPS layer 58 is provided on a pad 80 on the rear face. As shown in FIGS. 11 (C) and 12 (A 2 ), an IC chip 76 is incorporated in the cavity 74 and the IC chip 76 and the bonding pad 72 are connected with wire (gold wire) 78 . As shown in FIG. 11(D) and FIG. 12 (B 2 ), a connecting pins 82 are attached to a bump (corrosion resistant non-formation) 80 , which is an external terminal on the rear face, via solder 83 .
Example 21-2
[0166] Although like the example 2-1-1, the wire bonding pads (corrosion resistant layer formed) 72 are formed on the front face and the connection pin pad (corrosion resistant layer not formed) 80 , which is an external terminal, is disposed on the rear face, no OSP layer is formed on the pad 80 .
Example 2-1-3
[0167] Although like the example 2-1-1, the wire bonding pads (corrosion resistant layer formed) 72 are formed on the front face, the connection pin pads (corrosion resistant layer not formed) 80 , which are external terminals, are disposed on the rear face and the OSP layer is formed on the pad 80 , nickel-gold or nickel-palladium-gold is formed on the bonding pad (corrosion resistant layer) 72 .
Example 2-2-1
[0168] Like the example 2-1-1, as shown in FIG. 13 (A 1 ), the wire bonding pads (corrosion resistant layer formed) 72 and electronic component mounting pads (corrosion resistant layer not formed) 86 are provided on the front face, the connection pin pads (corrosion resistant layer not formed) 80 , which are an external terminal, are formed on the rear face and the OSP layer is formed on the electronic component mounting pad 86 and the connection pin pad 80 . As shown in FIG. 13 (A 2 ), an electronic component (chip capacitor) 90 is mounted on the electronic component mounting pad 86 on the front face and the connecting pin 82 is attached to the pad 80 on the rear face.
Example 2-3-1
[0169] Like the example 2-1-1, as shown in FIG. 14 (A 1 ), the wire bonding pads (corrosion resistant layer formed) 72 and the connection pin pads (corrosion resistant layer not formed) 80 are disposed on the front face and the OSP layer is formed on the connecting pin pad 80 . As shown in FIG. 14 (A 1 ), the IC chip 76 is mounted on the front face and the connecting pin 82 is attached to the pad 80 .
Example 2-4-1
[0170] Like the example 2-1-1, as shown in FIG. 15 (A 1 ), the flip chip bonding pads (corrosion resistant layer formed) 88 are formed on the front face and as shown in FIG. 15 (B 1 ), BGA pads (corrosion resistant layer not formed) 80 , which are an external terminal, are disposed on the rear face and the OSP layer is formed on the BGA pad 80 . As shown in FIG. 15 (A 2 ), the IC chip 76 is mounted on the front face via the flip chip bonding pad 88 and as shown in FIG. 15 (B 2 ), BGAs 84 are formed on the BGA pads 80 .
Example 2-4-2
[0171] Although like the example 2-4-1, the flip chip bonding pads (corrosion resistant layer formed) 88 are formed on the front face and the BGA pads (corrosion resistant layer not formed) 80 , which are an external terminal, are disposed on the rear face, no OSP layer is formed on the pad 80 .
Example 2-4-3
[0172] Although like the example 2-1-1, the flip chip bonding pads (corrosion resistant layer formed) 88 are formed on the front face and the BGA pads (corrosion resistant layer not formed) 80 , which are an external terminal, are disposed on the rear face and the OSP layer is formed on the pad 80 , nickel-gold or nickel-palladium-gold is formed on the flip chip bonding pad (corrosion resistant layer formed) 88 .
Example 2-5-1
[0173] Like the example 2-1-1, as shown in FIG. 15 (A 1 ), the flip chip bonding pads (corrosion resistant layer formed) 88 and the electronic component mounting pads (corrosion resistant layer not formed) 86 are provided on the front face and the BGA pads (corrosion resistant layer formed) 80 are disposed on the rear face and the OSP layer is formed on the electronic component mounting pads 86 and the BGA pads (corrosion resistant layer not formed) 80 . As shown in FIG. 15 (A 2 ), an electronic component (chip capacitor) 90 is mounted on the electronic component mounting pad 86 on the front face and the BGA 84 is formed on the BGA pad 80 on the rear face.
Example 2-6-1
[0174] Like the example 2-1-1, as shown in FIG. 17 (A 1 ), the flip chip bonding pads (corrosion resistant layer formed) 88 and the BGA pads (corrosion resistant layer not formed) 80 are disposed on the front face and the OSP layer is formed on the BGA pad (corrosion resistant layer not formed) 80 . As shown in FIG. 17 (A 1 ), the IC chip 76 is mounted on the front face and the BGA 84 is formed on the BGA pad 80 of the front face.
Comparative Example 2-1
[0175] According to the comparative example 2-1, the corrosion resistant layer (nickel-gold) was formed on all the pads 80 . Other matters were set equal to the example 2-1-1.
Comparative Example 2-2
[0176] According to the comparative example 2-2, the corrosion resistant layer (nickel-gold) was formed on all the pads 80 . Other matters were set equal to the example 2-4-1.
[0177] In a group of the example 2 and the comparative example 2, manufactured printed wiring boards were evaluated according to an item 2-A and printed wiring boards mounted with the IC chip were evaluated according to items 2-B and 2-C.
2-A. Reliability Test
[0178] Under the heat cycle condition (130° C./3 min and 55° C./3 min as a cycle), this cycle test was repeated up to 5,000 cycles and every other 500 cycles, a test piece was left for 2 hours after the test ended and the continuity test was carried out to verify whether or not continuity was obtained. Then, the number of cycles in which no continuity was verified were compared.
2-B. Continuity Test after Mounting
[0179] After a bare chip was mounted and an external terminal was disposed, the continuity test was carried out at 20 places at random and whether or there was any terminal whose resistance change ratio exceeded ±10% was verified. A test piece whose resistance change ratio exceeded ±10% was cut near its external connecting terminal to obtain a cross section and by observing a given pad with a microscope (×200), whether or not any crack existed on its conductive circuit or solder layer was verified.
2-C. Reliability Test after Mounting a Bare Chip
[0180] Under the heat cycle condition (130° C./3 min and 55° C./3 min as a cycle), this cycle test was repeated up to 5,000 cycles and every other 500 cycles, a test piece was left for 2 hours after the test ended and the continuity test was carried out at 10 places. Whether or not five or more circuits whose resistance change ratio exceeded ±10% existed was verified and the number of cycles in which there existed five or more such circuits was compared.
[0181] Although the invention has been disclosed in the context of a certain preferred embodiments, it will be understood that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments of the invention. Thus, it is intended that the scope of the invention should not be limited by the disclosed embodiments but should be determined by reference to the claims that follow. | This invention provides a multilayer printed wiring board in which electric connectivity and functionality are obtained by improving reliability and particularly, reliability to the drop test can be improved. No corrosion resistant layer is formed on a solder pad 60 B on which a component is to be mounted so as to obtain flexibility. Thus, if an impact is received from outside when a related product is dropped, the impact can be buffered so as to protect any mounted component from being removed. On the other hand, land 60 A in which the corrosion resistant layer is formed is unlikely to occur contact failure even if a carbon pillar constituting an operation key makes repeated contacts. | 76,604 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and is a continuation of U.S. patent application Ser. No. 10/989,285 filed Nov. 17, 2004, said application claiming priority to U.S. Provisional Patent Application Ser. No. 60/520,385 filed Nov. 17, 2003, entitled “Method and System for De-Identification of Patient Microdata,” each of which is assigned to the assignee of this application and is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention is directed to computer-related and/or assisted systems, methods, and computer program devices for facilitating efficient and effective use of patient and/or individual related information. More particularly, the present invention relates to techniques for facilitating efficient and effective use of patient and/or individual related information such as medical and/or health related information in compliance with Health Insurance Portability and Accountability Act (HIPAA) of 1996.
[0004] 2. Description of the Related Art
[0005] Some prior attempts have been made in unrelated fields in the healthcare industry to protect patient related information for various reasons. The prior art has not addressed what can be shared or disclosed based on HIPAA regulations.
[0006] The Knapp patent, U.S. Pat. No. 6,278,999, incorporated herein by reference, discloses an information management system for personal health digitizers (see FIG. 1 ) wherein a centralized database 100 collects and stores monitoring data from a large number of individuals and processing elements 101 - 108 perform statistical analysis of the collected data on a per consumer, population segment, or query-specific basis. The database is architected in a hierarchical manner to limit users' access to only that prepartitioned segment of the collected data that the particular class of user is authorized to analyze. Data is gathered from remotely located sources T 1 -Tn, comprised of individual consumers using Personal Health Digitizers to take readings on themselves or family members and downloading the data to the information management system IMS via a personal computer modem and Internet browser T 1 -Tn communicating with an interactive website WS and its data router DR. Alternatively, data can be communicated to the information management system IMS via consumer terminal equipment T 1 -Tn and the Pubic Telephone Switched Network PTSN.
[0007] Data from Personal Health Digitizers communicated to the information management system IMS can be accessed by those consumers who communicate the data via terminal equipment T 1 -Tn, by health care providers at their terminal equipment and servers S 1 -Sm, by institutions via their terminal equipment and servers I 1 -Ij, by medical practitioners, and others whom the consumer designates. These users, broken down into classes, can access the information management system IMS and its analysis functions only to the extent authorized by the consumer. Access control via the communication network PTSN is enforced by the use of database filters 103 - 106 architected to provide customized access to selected classes of users. The granularity of the data made available to the various classes of users is further selected and limited to prevent the users from deriving information about the consumer population that they are not entitled to receive. Data processing algorithms 108 operate on the raw physiological data collected from individual consumers and produce additional data that aids in identifying potential physiological problems. Interpretive processing systems 107 , either standard software database processes or neuromorphic systems, such as expert systems or neural networks, use pattern recognition operations to analyze the collected data for correlations with regard to cohort-based sets of criteria identified.
[0008] The Petculescu patent, U.S. Pat. No. 6,405,207, incorporated herein by reference, discloses a multidimensional, multilevel database system (see FIG. 2 ) wherein query syntax is used to operate a database engine 204 that extracts and aggregates in a report 206 only the data from those items that are specified in the query. A database client 201 provides facilities for multiple users to specify the data to be provided from the database 205 . The query 202 then passes to query processor 203 , where it is converted into sequenced operations performed by an execution engine 204 to obtain the specified data. The execution engine 204 then aggregates data into a report which the database client 201 displays. The query processor 203 , execution engine 204 , and database 205 are typically components residing in one or more central computers accessed by query software operating from individual personal computers that serve as database clients 201 .
[0009] The Zubelida patent, U.S. Pat. No. 6,397,224, incorporated herein by reference, discloses a system (see FIG. 3 ) for anonymously linking multiple data records 352 by double-encoding and assigning an anonymization code to data elements that can be used to identify an associated individual. Data records 352 are stored within an input database 354 , either conventional or computerized. Each record includes a plurality of identifying elements 356 including, for example, name birth date, address, ZIP code, telephone number, healthcare identifier, and the like. Identifying elements 356 of the data records 352 are encoded by two or more modules 358 that can be combined or integrated into a single software application or device. The identity reference encoding modules 358 operate in multiple steps. First, identifying elements 356 of a data record are broken into subsets 362 . The identifying elements are then translated into encoded identity references 360 by applying a cryptographic hash function or other hashing scheme, such as symmetric or public key cryptographic algorithms. This process can be repeated one or more times if the system 350 contains one or more additional identity reference encoding modules 358 , with the goal of reducing the probability of an unintended collision where two subsets 362 share the same encoded identity reference 360 .
[0010] The system 350 also includes an anonymization code database 368 that stores anonymization code 366 assignments (for example, serial numbers) associated with encoded identity references 360 and in turn a particular individual, group, or population. An anonymization code lookup module 364 utilizes a database query module 370 to retrieve the anonymization code 366 for each of the encoded identity references 360 . If no code is associated with a particular reference, an anonymization code assignment module 372 uses an anonymization code generation module 374 to assign a new, unique anonymization code 366 to each of the encoded identity references 360 that describe an individual, group or population. A database update module 376 is used to ensure that the assigned anonymization code 366 corresponds to the multiple encoded identity references 360 associated with an individual, group, or population. Finally, an anonymization code insertion module 380 inserts the assigned anonymization code 366 into the anonymized data record 382 . The inclusion of an identifying element removal module 378 is optional.
[0011] However, to the knowledge of the inventors, no attempts have been made to aggregate information about population, drug usage, health and/or medical related information in a manner that can be legitimately used. In addition, no attempts appear to have been made to aggregate health and/or medical related information in compliance with HIPAA regulations and/or in a manner that can be used to assist healthcare providers, health management companies, in research, healthcare and/or marketing, for example, in a small geographic area.
SUMMARY OF THE INVENTION
[0012] The present invention is a method and/or computer-implemented system to provide patient medical information in a way that in at least one embodiment, for example, conforms to HIPAA regulations regarding maximum re-identification risk. The invention is based on aggregation methods. The first aggregation method uses geographic proximity among patients, the second uses similarity of medical information. Other aggregation methods may be combined and/or utilize the overall aggregations process developed in the present invention to de-identify geographic, individual or patient-related data and/or conform to HIPAA regulations.
[0013] The first aggregation method, while maintaining low overall re-identification risk, also dramatically reduces the range of the risk of re-identification between zip codes. The second aggregation method provides more useful information than HIPAA “safe harbor” regulations, while also resulting in a much lower risk of re-identification.
[0014] The aggregation based on geographic proximity in the present invention includes as a first step ensuring that the input data is valid. This process begins by identifying patient records without zip codes. Those patient records without a zip code that cannot be corrected for are removed and/or filtered from the database. Next, the first unmerged zip code and its corresponding population is retrieved. If the population of the zip code is greater than the minimum needed to conform to HIPAA regulations (the safe limit), then the zip code is left alone. If the population is less than the safe limit, the zip code is then combined with nearby zip codes until the geographic area is greater than the safe limit. This is repeated until the aggregation process for all zip codes is finished.
[0015] The second method of aggregation, which is based on aggregating across medical information, has an initial process of clustering, followed by coding, and finally a process for providing the de-identified data. The process is implemented on a computer that is connected to a patient profile database, a cluster database, and a database of patient medical information. The clustering part of the de-identification process is intended to place the medical information into a hierarchy that is meaningful to the intended user of the de-identified information. The coding process is the second part of the de-identification method. The process of coding extracts the necessary information from the patient medical information database and the patient profile database to determine the prevalence of a medical characteristic in a zip code. This level of usage by zip code is then stored into the cluster database. The final part of the de-identification method is to receive request for zip codes or medical characteristics and respond with the appropriate de-identified information.
[0016] In one embodiment of the invention, a computer-implemented method for de-identifying data collected for patients, includes providing information representative of at least one patient, at least one medical characteristic associated with at least one patient, and a geographic area. This method also includes associating at least one patient with at least one geographic area, and creating at least one aggregated geographic area capable of de-identifying information through aggregating zero or more smaller geographic areas. Finally, the method aggregates information by medical characteristic and associates this information with the aggregated geographic area capable of de-identifying information.
[0017] In another embodiment of the invention, a computer-implemented method for de-identifying data collected for patients includes providing information representative of at least one patient, at least one medical characteristic associated with at least one patient, and a geographic area of the at least one patient. This method also provides at least one organizational structure for organizing medical characteristics, then associating the organizational structure with at least one geographical area and at least one medical characteristic. Information is then aggregated by the at least one medical characteristic and the at least one geographic area therein into the organizational structure.
[0018] In another embodiment of the invention, a computer-implemented method assesses compliance of de-identified data with data de-identification requirements, which includes safe harbor. The method includes the steps of quantifying a safe harbor risk for at least one data set by applying the safe harbor to the at least one data set, and then also applying at least one method of de-identifying data to the at least one data set. The method next compares the re-identification risk of the at least one de-identifying method to the safe harbor risk to determine whether the re-identification risk is lower than the safe harbor risk.
[0019] In another embodiment of the invention, two previous embodiments are combined together. The embodiment of aggregating medical information with an organizational structure is advantageously combined with the embodiment based on aggregating smaller geographic areas.
[0020] There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
[0021] In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
[0022] 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.
[0023] These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects 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
[0024] FIG. 1 is an illustration of a prior art information management system for personal health digitizers.
[0025] FIG. 2 is an illustration of a prior art multidimensional, multilevel database system.
[0026] FIG. 3 is an illustration of a prior art system for anonymously linking multiple data records.
[0027] FIG. 4 is a block diagram illustrating the overall system layout for aggregation based on medical information.
[0028] FIG. 5 is a flow chart illustrating the steps performed in organizing the medical characteristics into a hierarchy.
[0029] FIG. 6 is a flow chart illustrating the steps performed in coding the information contained in the patient records.
[0030] FIG. 7 is a flow chart illustrating the steps performed in providing the de-identified information in response to a specific request.
[0031] FIG. 8 shows a block diagram of a computer used for implementing one or more embodiments of the present invention, in accordance with a computer implemented embodiment.
[0032] FIG. 9 illustrates a block diagram of the internal hardware of the computer of FIG. 8 .
[0033] FIG. 10 illustrates a block diagram of an alternative computer of a type suitable for carrying out the present invention.
[0034] FIG. 11 is a flow chart illustrating the steps performed in aggregating medical information based on zip code
[0035] FIG. 12 is a diagram illustrating anomalous birth dates in the patient database.
DETAILED DESCRIPTION OF THE INVENTION
[0036] The following detailed description includes many specific details. The inclusion of such details is for the purpose of illustration only and should not be understood to limit the invention. Throughout this discussion, similar elements are referred to by similar numbers in the various figures for ease of reference. In addition, features in one embodiment may be combined with features in other embodiments of the invention.
[0037] The present invention is a method and/or computer-implemented system to provide patient medical information in a way that in at least one embodiment, for example, conforms to HIPAA regulations regarding maximum re-identification risk. The invention is based on aggregation methods. The first aggregation method uses geographic proximity among patients, the second uses similarity of medical information. Other aggregation methods may be combined and/or utilize the overall aggregations process developed in the present invention to de-identify geographic, individual or patient-related data and/or conform to HIPAA regulations.
[0038] The first aggregation method, while maintaining low overall re-identification risk, also dramatically reduces the range of the risk of re-identification between zip codes. The second aggregation method provides more useful information than HIPAA “safe harbor” regulations, while also resulting in a much lower risk of re-identification.
[0039] The aggregation based on geographic proximity method in the present invention, includes as a first step, providing de-identified data that is useful for marketing or other purposes, to ensure that the input data is valid. This process begins by identifying patient records without zip codes. Those patient records without a zip code that cannot be corrected for are removed and/or filtered from the database. The remaining records are treated as any other records that originally had zip codes. In an actual test database of patient information, records with out zip codes made up about 38.6% of the total patient records. The removal of any records without a zip code advantageously results in an under estimate of re-identification. It is less likely that a patient could be identified with public records, when that person does not have a zip code, as compared to one who does.
[0040] One group of records in the test database with missing zip codes, belonged to zip codes that could not be found in the 2000 Decennial Census. This accounted for 19.2% of zip codes but only 1.9% of patients of the baseline population. This can occur because these are new zip codes created since the last census and because the Census Bureau and the United States Post Office differ in their assignment of zip codes.
[0041] More information about how the zip code assignment differs between the United States Post Office and the Census Bureau may be found at http://pe.usps.gov/text/dmm/1606.htm and http://www.galaxymaps.com/wezipchg.htm. The information found at these sites was used to map the 2000 census data into the zip codes used by customers, which are United State Post Office zip codes. This mapping is preferred because not only is it more forward looking and current, but because it also maximizes the estimated risk of re-identification. It disaggregates the Census data into the United State Post Office zip codes rather than aggregating the United State Post Office data into Census zip codes. This disaggregation was also used to correct for patients who lived in new zip codes that had been formed out of previously existing zip codes.
[0042] The disaggregation proceeded as follows.
[0000] C i =Census population in i th code, and
[0000] P ij =Population in j th zip code formerly part of i th zip code, then
[0000] C ij =C i *P ij /Σ j P ij (summing over all zip codes formerly part of the i th zip code)
[0043] In general, a population was assigned to new zip codes that split the population of the old zip code equally among the new ones created out of it. It was assumed that when a new zip code was formed out of an old one, that the new zip code shared equally in the population. As before, this works to over estimate re-identification risk, since new zip codes areas are growing more quickly than already established zip codes, and therefore, ought to be assigned some proportionately higher degree of the population.
[0044] Another group of invalid zip codes, referred to as non-residential areas, are not associated with any geographic area. Instead they represent a specific office building, post office, of post office box. Very few of these zip codes were found in an actual database.
[0045] Incorrect zip codes are another source of invalid data. One case of this can be detected when an unrealistically high percentage of the population of are customers. Sometimes this means, an insurance carrier has used its zip code for the zip code of all its patients. A two step search was used to find these incorrect zip codes. The first step was to determine individual zip codes where an insurance company had significantly high over-representation. The second step was to decide if within such a zip code, whether a particular insurance carrier had an unrealistically high share of the total patient records. For the first determination, a straightforward studentization of the insurance company population was used as shown below:
[0000] C j =Census population for j th zip code
[0000] B j =Insurance company patient population for j th zip code
[0000] Exp j =Cj * (Total B Pop)/(Total Census Pop)
[0000] Score=( B j −Exp j )/sqrt(Exp j )
[0046] This determination was made, for example, on a purely statistical basis, although additional factors may also be utilized in the first determination. The second determination—identification of possibly aberrant carriers within an overrepresented zip code—was based on the expectation that carriers' shares of the insurance companies patients within a zip code should follow an exponential distribution given a uniform distribution of carriers' population. Since many, if not most, carriers are, however, geographically centered, it is likely that a given carrier might have the bulk of their business within a particular zip code.
[0047] Incorrect birthdates were another source of invalid data. These were removed to the extent possible. For instance, the current database has 4 times more centenarians than the 2000 Decennial Census recorded, and also contained a few individuals whose birthdates were in the future. Other dates, such as January 1st of every year, and the first and last day of each month, are also overrepresented. To correct for this, the residuals were calculated from a smooth trace running through all the data. One exemplary representation of the data is plotted, for example, in FIG. 12 .
[0048] The first method of aggregation for reducing re-identification risk is based on geographic proximity. The HIPAA “safe harbor” regulations require any geographic indicator to contain at least 20,000 people, and recommend that zip codes be aggregated to the 3 digit level to provide this floor. This level of aggregation has been determined to be generally unnecessary except for a very few zip codes. The present invention advantageously preserves more information than HIPAA “safe harbor” regulations by, for example in one embodiment, making geographic areas more uniform in population size. This is accomplished in one embodiment by merging zip codes only when necessary to achieve a population size whose risk of re-identification would conform to HIPAA “safe harbor” regulations.
[0049] The level of risk allowed by HIPAA “safe harbor” regulations was determined by creating a regression model based on the published re-identification risk numbers in the HIPAA legislation. A population of 500,000 can have a re-identification risk of 0.4%, a population of 100,000 can have an identification risk of 3%, and a population of 25,000 can have an identification risk of 10%, these numbers came from a study done by the National Center for Health Statistics. A log linear regression model was created based on these numbers for estimating re-identification risk:
[0000] Re-identification probability=10 (−0.66048*sqrt(n/1000))
[0050] From this model it is estimated that the 2000 Decennial Census had an average re-identification risk of 0.85%, with a maximum risk of 8.77% for any one zip code. The estimate for the 1990 Decennial census was an average re-identification risk of 1.01%. The present invention here advantageously results in less risk than the HIPAA legislation models would have resulted in for the 2000 Census data when using the aggregation processes described herein.
[0051] This re-identification risk estimate can be made more accurate by accounting for the imperfections in actual data. For example in one embodiment, this imperfection in data due to reasons explained above lower the re-identification risk by about 10%. This is because missing zip anomalies accounted for 9.11% of the data, incorrect zip codes inserted by the insurance accounted for 3.48%, age and birth date anomalies for 1.73%, and age distribution for 3.87%. The overall effect of this is (1−3.48%)*(1−1.73%)*(1+3.87%)/(1+9.11%)=90.30%, or lowering re-identification risk by 10%.
[0052] In one embodiment of the present invention, the estimated re-identification risk was 0.16%. This was derived from the baseline patient population containing 448,883 unique 5 digit zip code and birth year combinations. This resulted in a naive re-identification risk of 0.72%. But the population of a particular medical provider is not that same as the entire population. It was 4.62 smaller than the national population, meaning the estimated re-identification risk was 0.72%/4.62=0.16%, since not every patient record will also be unique in the national population. This low rate of re-identification means gender information could also be added.\
[0053] Aggregating to the 3 digit level for zip codes is generally unnecessary to meet the level of risk allowed, except for a very few zip codes. Matching records using zip code and birth year results in a very low risk of re-identification even when using the entire 5 digit zip code. This hypothesis was validated using actual public information along with actual patient information. Software and data was purchased from Pallorium corporation, along with their “People Finder” software for the states of New York and Texas. The data CDs contain a combination of driver's license, voter registration, and property tax records, together with name, address phone number and birth date for each record. This information was compared to the information in the patient database to see how many unique matches occurred, which meant someone could be re-identified. The results are shown in the table below, showing the experimental re-identification risk of 0.01%. At that risk level, gender information can easily be added in compliance with HIPAA “safe harbor” regulations, but birth month, which would increase risk by 12 times, cannot. This means where age, gender, and 5 digit zip code are the only fields in a record matched in a public use data file, de-identification risk can meet HIPAA “safe harbor” regulations.
[0000]
TABLE
Actual Re-Identification Risk for 5-Digit Zip and Birth year
New York
(%)
Texas
(%)
Patient database
2,844,109
3,524,857
Unique records patient
24,490
0.86%
26,321
0.75%
database
Public: Found
15,847
0.56%
18,534
0.53%
Public: “Unique”
1,096
0.04%
2,038
0.06%
Public: True Match
299
0.01%
344
0.01%
2000 Census (estimated risk)
0.84%
0.84%
[0054] Turning to FIG. 11 , the process of aggregation based on geographic proximity is described. In FIG. 11 , the process starts by retrieving the first unmerged zip code and its corresponding population 1102 . If the population of the zip code is greater than the minimum needed to conform to HIPAA regulations (the safe limit), then the zip code is left alone 1103 . For example, with one embodiment of the invention, which contained a database with the prescription purchases of over 100 million patients, a zip code with 250,000 people is sufficiently large to conform to HIPAA “safe harbor” regulations. If the population is less than the safe limit 1103 , the zip code is then combined with nearby zip codes containing the same first 4 digits 1104 , until the geographic area is greater than the safe limit 1105 , 1106 . In one embodiment of the invention, this process of combining zip codes was done using a “greedy” algorithm. If the population is still not above the safe limit after merging with all zip code with the same first 4 digit, then it is combined with nearby zip codes with the same first 3 digits 1107 until it is greater than the safe limit 1108 , 1109 . Regardless, if after merging with all other zip codes with the same first 3 digits the population is greater than the safe limit, the aggregation process is finished. This is repeated until the aggregation process for all zip codes is finished 1110 . Other modified version of this process may also be used in the present invention and/or in combination. For example, instead of combining population with the same first 3 digits, other populations may be added to increase the population for the safe limit.
[0055] The second method of aggregation, which is based on aggregating across medical information, has an initial process of clustering, followed by coding, and finally a process for providing the de-identified data. The overall design of aggregation based on medical information is shown in FIG. 4 . The process is implemented on a computer 401 that is connected a patient profile database 405 , a cluster database 407 , and a database of patient medical information 413 . The patient profile database stores profile information about patients that is partially independent of their medical information. This includes information like name, address, zip code, etc. The patient medical information database contains their medical information, which could be information such as prescription purchases, current medical conditions, and/or genetic traits. Finally, the cluster database 407 stores the information that is produced during the clustering and coding parts of the aggregation process.
[0056] If additional information is needed during any phases of the aggregation process, it can be accessed, for example, at public databases 409 that are connected through the Internet 411 . Information such as census data, population studies, and surveys, can be useful in preparing and filtering patient profile and patient medical information databases.
[0057] The clustering part of the de-identification process is intended to place the medical information into a hierarchy that is meaningful to the intended user of the de-identified information. For one embodiment of the invention, the medical information comprised drugs that were placed into a hierarchy based on similarity of drugs. Other types of medical information such as specific medical conditions or genetic traits may optionally be placed into their own hierarchy. For one embodiment of the invention, based on drug usage, prescription purchases of all drugs were placed into a hierarchy that began with the standard 79 second level categories of the uniform formulary therapeutic classification scheme. This is a uniform system of drug classification that many health insurance plans have adopted. These 79 second level categories are then advantageously grouped into one of 30 third level clusters. Those 30 clusters are then grouped into one of 13 fourth level clusters, and finally, those 13 clusters are grouped into one of 4 meta-clusters. In one embodiment of the invention, a single third level cluster optionally contains beta-blockers, direct acting miotics, glaucoma drugs, and sympathomimetics. A single meta-cluster optionally contains sub-clusters like antihistamines, migraine medication, and immunosuppressants.
[0058] As illustrated in FIG. 5 , the clustering process begins by associating the medical information with the proper lowest level category 503 . The next step in the process, grouping the lowest level categories into the higher level clusters is done, for example, by determining points of similarity that exist between the separate levels 505 . This determination is made by using an agglomerative clustering algorithm The algorithm is one which places the two closest objects together in one cluster; then the two next closest objects (which can themselves be clusters), and so on, until all objects are in one large cluster.
[0059] Once all the second level categories have been associated with higher level clusters 507 , they are then processed 509 and associated with one of the meta-clusters 511 . The grouping into the meta-clusters is more straightforward because of the breadth of the categories. In one embodiment of the invention 4 meta-clusters were used: acute, chronic, dermatological, and miscellaneous, although any number of meta-clusters may be used. After the clusters have been associated with a meta-cluster 513 , all this information regarding the hierarchy structure is stored 515 in the cluster database. The clustering process is then finished 517 . The coding process, shown in FIG. 6 , is the second part of the de-identification method. It combines, in one embodiment, the patient medical information database, the patient profile database, and the cluster database. The process of coding extracts the necessary information from the patient medical information database and the patient profile database to determine the prevalence of a medical characteristic in a zip code. In one embodiment of the invention, involving a prescription database, the information extracted corresponds to whether there is a high/average/low usage for a drug in a zip code. This level of usage by zip code is then stored into the cluster database. The specific combination of high/average/low usage may be determined by the application, user, drug, condition, and the like.
[0060] The process of coding 601 retrieves a zip code 603 , it then associates one path of the cluster hierarchy with the zip code 605 . In one embodiment of the invention, an association is performed with one combination of a second level category, a third and fourth level cluster, and a meta-cluster. Additional associations and/or combinations may optionally be used. The process of retrieving zip codes and associating them with the hierarchy is automatic since each zip code is eventually associated with each possible path. The next step is to retrieve a patient profile record from the zip code, and the corresponding record from the patient medical information database 607 . A counter is then incremented that corresponds to the characteristic of the patient's medical information that is of interest 609 . In one embodiment of the invention, the counters for a drug are incremented if a patient bought a prescription for that drug. This is optionally continued until all patient profile records in the zip code have been processed 611 . The usage in the zip code is then compared to the expected usage for the zip code, and the result of high/average/low is stored in the cluster database 615 . This process continues until all zip codes have been processed 613 . The coding process is then finished 617 . Alternative combinations or sequences of the above described coding process may optionally be used.
[0061] The final part of the de-identification process is shown in FIG. 7 . This phase retrieves the de-identified data in response to a request to identify an area with a high/average/low level of a medical characteristic 701 . The process begins by receiving a request for a characteristic 703 , then determining what path in the hierarchy that characteristic has been associated with 705 . Next, for the requested medical characteristic, the level of prevalence for all zip codes is retrieved 707 . In one embodiment of the invention, this corresponds to the amount of a drug purchased in that zip code. This retrieval process can be accomplished by retrieving all records for a characteristic, since in the previous clustering process a prevalence level for each zip code of a medical characteristic was stored in the cluster database associated with a hierarchy path. Finally, a response listing is provided 709 , and the process is finished 711 .
[0062] Many other types of response listings are also possible after the clustering and coding processes have organized information in the database. For instance, instead of returning a prevalence level by zip code for a medical characteristic, the opposite process could be easily done. The user could make a request for the prevalence level of a medical characteristic for a zip code, and that information could be returned for each level in the cluster hierarchy. In addition, alternative and/or modified steps can be used to filter cluster, and/or aggregate information to appropriately de-identify information in accordance with the present invention.
[0063] The present invention is advantageously implemented or, or assisted with on a computer. FIG. 8 is an illustration of a computer 858 used for implementing the computer processing in accordance with a computer-implemented embodiment of the present invention. The procedures described herein may be presented in terms of program procedures executed on, for example, a computer or network of computers.
[0064] Viewed externally in FIG. 8 , computer 858 has a central processing unit (CPU) 868 having disk drives 869 , 870 . Disk drives 869 , 870 are merely symbolic of a number of disk drives that might be accommodated by computer 858 . Typically, these might be one or more of the following: a floppy disk drive 869 , a hard disk drive (not shown), and a CD ROM or digital video disk, as indicated by the slot at 870 . The number and type of drives varies, typically with different computer configurations. Disk drives 869 , 870 are, in fact, options, and for space considerations, may be omitted from the computer system used in conjunction with the processes described herein.
[0065] Computer 858 also has a display 871 upon which information may be displayed. The display is optional for the computer used in conjunction with the system described herein. A keyboard 872 and/or a pointing device 873 , such as a mouse 873 , may be provided as input devices to interface with central processing unit 868 . To increase input efficiency, keyboard 872 may be supplemented or replaced with a scanner, card reader, or other data input device. The pointing device 873 may be a mouse, touch pad control device, track ball device, or any other type of pointing device.
[0066] Alternatively, referring to FIG. 10 , computer 1058 may also include a CD ROM reader 1095 and CD recorder 1096 , which are interconnected by a bus 1097 along with other peripheral devices 1098 supported by the bus structure and protocol. Bus 97 serves as the main information highway interconnecting other components of the computer. It is connected via an interface 1099 to the computer 1058 .
[0067] FIG. 9 illustrates a step diagram of the internal hardware of the computer of FIG. 8 . CPU 975 is the central processing unit of the system, performing calculations and logic operations required to execute a program. Read only memory (ROM) 976 and random access memory (RAM) 977 constitute the main memory of the computer. Disk controller 978 interfaces one or more disk drives to the system bus 974 . These disk drives may be floppy disk drives such as 979 , or CD ROM or DVD (digital video/versatile disk) drives, as at 980 , or internal or external hard drives 981 . As previously indicated these various disk drives and disk controllers are optional devices.
[0068] A display interface 982 permits information from bus 974 to be displayed on the display 983 . Again, as indicated, the display 983 is an optional accessory for a central or remote computer in the communication network, as are infrared receiver 988 and transmitter 989 . Communication with external devices occurs using communications port 984 .
[0069] In addition to the standard components of the computer, the computer may also include an interface 985 , which allows for data input through the keyboard 986 or pointing device, such as a mouse 987 .
[0070] The system according to the invention may include a general purpose computer, or a specially programmed special purpose computer. The user may interact with the system via e.g., a personal computer or over PDA, e.g., the Internet, an intranet, etc. Either of these may be implemented as a distributed computer system rather than a single computer. Similarly, the communications link may be a dedicated link, a modem over a POTS line, and/or any other method of communicating between computers and/or users. Moreover, the processing could be controlled by a software program on one or more computer systems or processors, or could even be partially or wholly implemented in hardware.
[0071] Further, this invention has been discussed in certain examples as if it is made available to a single user. The invention may be used by numerous users, if preferred. The system used in connection with the invention may rely on the integration of various components including, as appropriate and/or if desired, hardware and software servers, database engines, and/or other content providers.
[0072] Although the computer system in FIG. 8 is illustrated as having a single computer, the system according to one or more embodiments of the invention is optionally suitably equipped with a multitude or combination of processors or storage devices. For example, the computer may be replaced by, or combined with, any suitable processing system operative in accordance with the principles of embodiments of the present invention, including sophisticated calculators, hand held, laptop/notebook, mini, mainframe and super computers, as well as processing system network combinations of the same. Further, portions of the system may be provided in any appropriate electronic format, including, for example, provided over a communication line as electronic signals, provided on floppy disk, provided on CD Rom, provided on optical disk memory, etc.
[0073] Any presently available or future developed computer software language and/or hardware components can be employed in such embodiments of the present invention. For example, at least some of the functionality mentioned above could be implemented using Visual Basic, C, C++ or any assembly language appropriate in view of the processor being used. It could also be written in an interpretive environment such as Java and transported to multiple destinations to various users.
[0074] As another example, the system may be a general purpose computer, or a specially programmed special purpose computer. It may also be implemented to include a distributed computer system rather than as a single computer; some of the distributed system might include embedded systems. Similarly, the processing could be controlled by a software program on one or more computer systems or processors, or could be partially or wholly implemented in hardware.
[0075] As another example, the system may be implemented on a web based computer, e.g., via an interface to collect and/or analyze data from many sources. It may be connected over a network, e.g., the Internet, an Intranet, or even on a single computer system. Moreover, portions of the system may be distributed (or not) over one or more computers, and some functions may be distributed to other hardware, and still remain within the scope of this invention. The user may interact with the system via e.g., a personal computer or over PDA, e.g., the Internet, an intranet, etc. Either of these may be implemented as a distributed computer system rather than a single computer. Similarly, a communications link may be a dedicated link, a modem over a POTS line, and/or any other method of communicating between computers and/or users. Moreover, the processing could be controlled by a software program on one or more computer systems or processors, or could even be partially or wholly implemented in hardware.
[0076] User interfaces may be developed in connection with an HTML display format. It is possible to utilize alternative technology for displaying information, obtaining user instructions and for providing user interfaces.
[0077] The system used in connection with the invention may rely on the integration of various components including, as appropriate and/or if desired, hardware and software servers, database engines, and/or other process control components. The configuration may be, alternatively, network-based and may, if desired, use the Internet as an interface with the user.
[0078] The system according to one or more embodiments of the invention may store collected information in a database. An appropriate database may be on a standard server, for example, a small Sun™ Sparc™ or other remote location. The information may, for example, optionally be stored on a platform that may, for example, be UNIX-based. The various databases may be in, for example, a UNIX format, but other standard data formats may be used. The database optionally is distributed and/or networked.
[0079] Although the system is illustrated as having a single computer, the system according to one or more embodiments of the invention is optionally suitably equipped with a multitude or combination of processors or storage devices. For example, the computer may be replaced by, or combined with, any suitable processing system operative in accordance with the principles of embodiments of the present invention, including sophisticated calculators, hand held, laptop/notebook, mini, mainframe and super computers, one or more embedded processors, as well as processing system network combinations of the same. Further, portions of the system may be provided in any appropriate electronic format, including, for example, provided over a communication line as electronic signals, provided on floppy disk, provided on CD ROM, provided on optical disk memory, etc.
[0080] The invention may include a process and/or steps. Where steps are indicated, they may be performed in any order, unless expressly and necessarily limited to a particular order. Steps that are not so limited may be performed in any order.
[0081] To confirm the advantages of the present invention, experiments were carried oui on actual data. The first aggregation method, which was based on geographic proximity, was applied to an actual patient database. This aggregation scheme resulted in about the same number of zip areas ( 889 ) as under the HIPAA “safe harbor” rules ( 875 ), which recommends 3 digit zip codes. More importantly, while not significantly affecting the overall risk, it resulted in a dramatic reduction in maximum risk as the table below shows.
[0000]
% Unique records when applied to actual patient database
Average Risk
Minimum Risk
Maximum Risk
HIPAA “Safe Harbor”
.78%
.00%
9.61%
aggregation
Zip code aggregation
.77%
.36%
1.14%
[0082] The second aggregation method, which was based on aggregation across medical information, was run on approximately 700 million actual prescription drug claims made during the 2000-2001 year. This aggregation scheme, applied to the 4 level hierarchy, ideally produces 81 different types of zip codes. There are 3 different levels for each of the four meta-clusters, which results in 3×3×3×3=81 types. At this level of aggregation, the method results in only 148 unique age type pairs, or 0.00024% of the population. This means when age, gender, and zip code are the only fields in a record matched to a public use data file, aggregation based on drug usage can conform to HIPAA “safe harbor—when providing birth •year, birth month; and gender. Further, ages over 90 do not need to be re-coded or aggregated in the de-identified microdata file. This demonstrates that aggregation based on drug usage can preserve useful information, while dramatically reducing re-identification risk in accordance with the embodiments of the present invention.
[0083] The many features and advantages of the embodiments of the present invention are apparent from the detail specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention that fall within the true spirit and scope of the invention. Further, since numerous modifications and variations were readily occurred to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents maybe resorted to, falling within the scope of the invention. | A computer-implemented method de-identifies data collected for patients. In at least one embodiment, the method comprises the sequential, non-sequential and/or sequence independent steps of providing information representative of at least one patient, at least one medical characteristic associated with at least one patient thereto, and a geographic area of the at least one patient, and providing at least one organizational structure for organizing medical characteristics. The method also includes associating the at least one organizational structure with at least one geographical area and at least one medical characteristic, and aggregating, in the at least one organizational structure, said information by medical characteristic and the at least one geographic area therein. Various alternative embodiments are additionally disclosed. | 53,450 |
This application claims the benefit of U.S. provisional patent application No. 60/410,782, filed Sep. 13, 2002.
BACKGROUND OF THE INVENTION
This invention relates to a machine for generating energy from a wind source. More particularly, this invention relates to a machine having a rotor that is caused to rotate around a vertical axis by a wind source. The rotor may be coupled to a dynamo-electric generator in order to produce electric power for downstream consumption.
Currently, machines for generating energy from wind sources can include large wind turbines mounted at wind sites, along with various deflectors placed upstream of the turbine. Such arrangements can be difficult to install at the wind sites, as the placement of the various deflectors can be complex. In addition, such an arrangement can be unaesthetic and can lessen the beauty of the landscape at the wind site.
Accordingly, it would be desirable to provide a machine for generating energy from a wind source having a casing structure within which a rotor having a vertical axis of rotation is positioned.
SUMMARY OF THE INVENTION
In accordance with the present invention, a machine for generating energy from a wind source is provided having a casing structure within which a rotor having a vertical axis of rotation is positioned.
The solutions of the present invention simplify the construction process of the machinery and its installation at a wind site. Furthermore, the machinery may be adjusted to optimize the power extraction from a wind source, and achieves a minimal ecological impact when installed at the wind site. The machinery is applicable for a wide range of power rating consumptions (e.g., from ratings of domestic applications to ratings of primary wind power stations).
In some embodiments of the present invention, the machine for generating usable energy from a wind source has a casing structure. A rotor having a blade structure is positioned within the casing structure and has a substantially vertical axis of rotation. The casing structure may define an air inlet upstream of the rotor that is oriented with respect to a prevailing wind direction and an air outlet downstream of the rotor. The casing structure may have a main passage through which air flows and interacts with the blade structure. The casing structure may have first and second side passages that are delimited by first and second sidewalls of the casing structure, respectively. The first and second side passages may converge toward one another near the air outlet forming a zone of low pressure downstream of the rotor.
Further features of the invention, its nature and various advantages will be more apparent from the accompanying drawings and the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial perspective view of the energy generating machine of the present invention, with certain parts removed to show other parts that would otherwise be hidden.
FIG. 2 is a view as seen from direction 2 — 2 of FIG. 1 .
FIG. 3 is an enlargement of portion 3 of FIG. 2 .
FIG. 4 is a sectional view as seen from direction 4 — 4 of FIG. 2 , and which also shows the parts which have been removed in FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIGS. 1-3 , rotor 10 is located in passage 12 for rotation around vertical axis 14 in direction 15 when driven by a wind source (e.g., a natural wind source). Vertical axis 14 is substantially perpendicular to upper cover plate 16 and lower cover plate 18 of general casing structure 20 . Upper cover plate 16 and lower cover plate 18 may be substantially horizontal, and therefore parallel to a ground plane that supports general casing structure 20 . (In FIG. 1 , upper cover plate 16 is not shown in order to show other parts of the machine that would otherwise be hidden.)
Rotor 10 may include a blade structure. In the example shown in the FIGS., the blade structure of rotor 10 includes a plurality of blades 22 that are cantilevered from rotation shaft 24 . Blades 22 may be panels having a concave configuration, as shown in the FIGS. Blades 22 may have other configurations, such as a spiral shape, to increase the power extraction from the wind source. Passage 12 may be delimited laterally by opposite side walls 26 and 28 and vertically by upper and lower cover plates 16 and 18 , respectively.
Side walls 26 and 28 extend from inlet opening 30 of passage 12 to outlet opening 32 of passage 12 . Side walls 26 and 28 may be substantially parallel to each other in portion 34 of passage 12 , while sidewalls 26 and 28 may converge towards each other in portion 36 of passage 12 . Inlet opening 30 faces a prevailing wind direction in order to collect and achieve air flow F in portion 34 of passage 12 .
In portion 34 , the path of air flow F is initially parallel to sidewalls 26 and 28 . Air flow deflector members, consisting of upstanding panels 38 - 43 , are spaced apart at predetermined positions in portion 34 in order to partially surround rotor 10 along a circular sector 46 . Portions F i of air flow F are deflected by panels 38 - 43 , thereby causing the air particles of flow F to fill compartments 48 of the rotor. Compartments 48 are delimited by blades 22 and upper and lower cover plates 16 and 18 , respectively. The configurations of panels 38 - 43 (shown as both concave and straight in the FIGS.), and their orientation, cause the air particles to impinge on the surfaces of blades 22 at predetermined angles. The predetermined angles influence the resultant driving force achieved on rotor 10 by the wind source. The air particles that enter compartments 48 rotate with rotor 10 and run along blades 22 until they are discharged through passage 50 . Thus, the air particles lose their quantity of motion or energy in order to drive rotor 10 .
Narrow passages 52 and 54 , which are respectively delimited by sidewalls 26 and 28 , are on opposite sides of the circular sector 46 occupied by panels 38 - 43 . Upper and lower cover plates 16 and 18 , respectively, vertically delimit passages 52 and 54 .
Upstanding casing structures 56 and 58 are located in another circular sector 60 surrounding rotor 10 . Face 62 of casing structure 56 , together with panel 38 , form passage 64 . Similarly, face 66 of casing structure 58 , together with panel 43 , form passage 68 . Face 70 of casing structure 56 surrounds a portion of rotor 10 . Similarly, face 72 of casing structure 58 surrounds another portion of rotor 10 . Passage 50 is formed between face 74 and face 76 . Face 78 and sidewall 26 complete narrow passage 52 . Similarly, face 80 and sidewall 28 complete narrow passage 54 . Preferably, passage 50 is centered on axis 82 , and narrow passages 52 and 54 are spaced symmetrically apart with respect to axis 82 , as shown in the FIGS.
By means of the described arrangement, portions of air flow F that have not entered rotor 10 (see portions of air flow F referenced as F 1 and F 2 ) will run through narrow passages 52 and 54 to create a low pressure region in portion 36 . The low pressure region in portion 36 induces the extraction of air particles from rotor 10 through passage 50 . The extraction occurs when a compartment 48 of rotor 10 is facing passage 50 . The sectional size of passage 50 influences the average speed of the air particles when moving with rotor 10 . More particularly, a restricted sectional size of passage 50 , compared to the total sectional size of passages formed by panels 38 - 43 on sector 46 , increases the average speed of the air particles rotating with rotor 10 . The increase in the average speed of the air particles extracts more rotation power for rotor 10 , which consequently increases the electric power that can be obtained for downstream consumption.
The low pressure region 36 extends beyond outlet opening 32 so that the air particles of flow F are ultimately discharged from passage 32 .
Rotor 10 is supported for rotation in direction 15 by supporting shaft 24 in bearings 84 and 86 , seated in upper cover plate 16 and lower cover plate 18 , respectively (see FIG. 4 ). Dynamo-electric generator 88 may be coupled to shaft 24 , as shown in FIG. 4 .
External plates 90 and 92 , which have a cylindrical shape, surround side walls 26 and 28 . As a result, general casing structure 20 has a homogenous cylindrical appearance to the external observer. In addition, the resulting cylindrical form of general casing structure 20 presents low disruption to air flow investing the entirety of general casing structure 20 .
Lower case plate 18 may be provided with wheels 94 , which may be supported and guided by ground rail 96 . Ground rail 96 may be circular in order to rotate lower case plate 18 around a vertical axis of the machinery. Circular rack 98 , which lines lower cover plate 18 and is concentric to the vertical axis of the machinery, may be engaged by pinion 100 of motor 102 . By rotation of motor 102 , general casing structure 20 may be rotated around the vertical axis of the machinery to orient inlet opening 30 with respect to a prevailing wind direction, thereby maximizing power extraction from the wind source.
The prevailing wind direction may be sensed by a wind direction sensor that supplies information signals which may be used by a control and regulation unit to drive motor 102 , resulting in calculated rotations that orient inlet opening 30 with respect to the prevailing wind direction. The external cylindrical form of general casing structure 20 offers low air obstruction when rotating general casing structure 20 around the vertical axis of the machinery to orient inlet opening 30 with respect to the prevailing wind direction.
Limiting the power extraction from the wind source in situations of high wind speeds may be achieved by rotating baffles 104 towards each other to form a diverging passage for the air flow reaching and passing through rotor 10 . A rotated position of baffles 104 is shown by the dashed lines in FIG. 2 .
The inclusion of rotor 10 within general casing structure 20 greatly reduces the noise level that rotor 10 produces during rotation caused by the wind source. Furthermore, protection grids (not shown) may be installed across inlet opening 30 and outlet opening 32 to prevent humans and animals from entering passage 12 . The protection grids would be visible and would present low air obstructions to the air flow F needed in passage 12 .
Higher power ratings of the machinery may be achieved by increasing the overall sizes of rotor 10 and passage 12 . The major increases in size can be in the diameter of rotor 10 and in the plan dimensions of passage 12 . These alterations would result in a lower height of general casing structure 20 with respect to the height of traditional wind driven machinery having the same power rating. An increase of the power ratings can also be achieved by mounting multiple units, such as the unit shown in FIG. 4 , one above the other in order to form a vertical column of small plan occupancy.
The machine of the present invention may be installed in various locations where it is desired to produce electric power from a wind source. For example, the machine of the present invention may be installed on a roof of a tall building in an urban setting, thereby taking advantage of the high winds present at such a height and making efficient use of available space.
Thus, a wind powered energy generating machine is provided. One skilled in the art will realize that the present invention can be practiced by other than the described embodiments, which are presented for purposes of illustration and not of limitation, and that the present invention is limited only by the claims which follow. | A machine for generating usable energy from a wind source is provided. The machine includes a casing structure that may define an air inlet oriented with respect to a prevailing wind direction and an air outlet. The casing structure may be substantially cylindrical. A rotor having a blade structure is positioned within the casing structure and has a substantially vertical axis of rotation. The casing structure may include two side passages for creating a zone of low pressure downstream of the rotor near the air outlet. | 12,210 |
SUMMARY OF THE INVENTION
The basic purpose of the invention is to provide a training device for interactively guiding a tennis racquet by means of exercising a towing force on a cord, which is connected with the tennis racquet, in the sequence corresponding to some certain points and phases of the swing during the execution of the strokes. In particular, for the serve, fore-, and backhand smash, fore-, and backhand slice, and volley strokes.
This is achieved according to the invention with a training device, which includes a vertically adjustable support that is telescopically connected with a vertical guide pole that is fixed on the wall. On the upper part of the support is arranged a frame for supporting a shaft of a swivel-arm that is constructed such that the swivel-arm is slanted upward.
On the proximal end of the swivel-arm, a weight-balance is fixed that turns the swivel-arm into the upper position in which the swivel-arm is automatically arrested by means of an arresting mechanism fixed on the frame. On the distal end of the swivel-arm is fixed a ring, which includes a suspension arrangement to hang a ball.
On the support and the swivel-arm are arranged some pulleys and devices to exercise the towing force on the cord, which is connected with the tennis racquet through a stirrup. The mechanisms for exercising the towing force on the cord are adjustable to define the parameters such as direction, quantity, and timing of the towing force according to the kind of stroke, the body height of the player and the player's skill level.
The motto of the present training device is “Practice slowly, learn quicker”. That means: the player is not under pressure to respond quickly and can thereby feel and sense the whole movement involved.
The ball being placed in the ideal hitting zone gives even a beginner the possibility of hitting the ball in the very first practice. The player is able to watch in slow motion the way in which the racquet face comes to the ball. In particular, it is very important to watch the difference between the flat-, slice- and topspin serve swing at the meeting point.
The prescribed position of the hanging ball is defined by means of a stepping plate with marked footprints placed at certain distances from the hanging ball or from the ring. During serve training, the ring allows the player to visualize the ideal tossing zone, and both the direction and the height of the toss for the different kinds of serves, i.e., flat-, slice-, and topspin serves.
During training of the fore- and backhand slice and volley, the marked footprints give the player the possibility of training or learning the footwork in the sequence corresponding to the swing.
The cord, by being connected with the tennis racquet distinguishes the present training device, in particular by the interactive guiding of the tennis racquet during the swing.
The other portion of the cord runs through some pulleys and a moveable releasing device to an anchor point on the support. The towing force on the cord is exercised by means of an elastic rope that is fixed in the moveable releasing device. In addition, a trigger is mounted on the support to fix and release a bead that is pressed on the cord at a certain distance from the anchor point.
At the waiting stance for serve training, the bead is fixed in the trigger and the portion of the cord between the anchor point and the bead is strained by means of the elastic rope, the proximal end of the swivel-arm is free from the arresting mechanism to let it turn and thereby let a player pull the racquet down.
From the waiting stance to the end of the back swing (the upper, at-rest position of the swivel-arm), the weight-balance on the proximal end of the swivel arm exercises a relatively weak force on the cord to let same guide the tennis racquet in the correct way to the end of the back swing at which the proximal end of the swivel-arm is arrested.
Thus, the tennis player is forced to go through the prescribed position on the end of the back swing because the defined length of the cord does not allow dropping the right elbow lower than shoulder height and tilting the racquet shaft to the wall.
At the end of the back swing, there is no hindrance from the cord so as to allow the player to execute the next phase of the swing (i.e. a loop) in the correct direction back, downward. The construction of the stirrup does not allow the racquet and arm to go in the wrong direction, but rather allows the arm to drop the head of the racquet in the correct way, that is, to the small of the back.
At the lowest point of the loop, after a short plucking of the cord which releases the trigger, the towing force will be activated overall on the cord and a player will be interactively led to the next prescribed position of the swing, which includes the full stretching of the arm and body.
At the full stretching of the arm and body (the point is adjustable), the moveable releasing device enters into a releasing port that is adjustably mounted on the lower part of the support, and through this interaction the cord will be set free from the releasing device so as to allow the player to hit the hanging ball and follow-through without hindrance from the cord.
All points and phases of the swing are adjustable by means of shifting both the trigger and the releasing port.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be discussed in detail hereinafter in connection with the drawings, whereby the individual aspects and advantages of the invention, whether or not they have been discussed above, can be recognized more clearly. All figures of the drawings relate to the same preferred exemplary embodiment of the training device of the invention, whereby:
FIG. 1 is a side view of the device for serve training,
FIG. 2 is a top view of FIG. 1,
FIG. 3 shows the tennis player in position with a racquet at the lowest point of the loop of the serve swing,
FIG. 4 is an opposite side view of the device for slice, volley, and smash training,
FIG. 5 is a top view of FIG. 4 of the stepping plate for slice, volley and smash training,
FIG. 6 is a side view of FIG. 7,
FIG. 7 is a front view of the grip of the tennis racquet with the stirrup,
FIG. 8 is an enlarged fragmentary view of a top part of the holder shown in FIG. 1,
FIG. 9 is a cross-sectional view along the line IX—IX of FIG. 8,
FIG. 10 is an enlarged, fragmentary view of a lower part of the holder shown in FIG. 1,
FIG. 11 is a cross-sectional view along the line XI—XI of FIG. 10,
FIG. 12 is a longitudinal cross-sectional view along the line XII—XII of FIG. 13,
FIG. 13 is an enlarged, fragmentary front view of the lower part of the holder shown in FIG. 1,
FIG. 14 is an enlarged, fragmentary view of the top part of the holder shown in FIG. 4,
FIG. 15 is an enlarged, fragmentary front view of the releasing port shown in FIG. 14, and
FIG. 16 is a side view of FIG. 15 .
DETAILED DESCRIPTION
According to the basic design illustrated in FIGS. 1, 2 , 4 and 5 , the training device illustrated in the drawings includes a vertically adjustable support 1 , which is telescopically connected with a vertical guide pole 2 that is fixed by means of two pylons 3 on a wall 4 .
The support 1 can be moved along the guide pole 2 and fixed by hand at the desired height by means of a fixture 5 . Smooth sliding of the support 1 is provided by means of two plastic cuffs 6 which are firmly fixed on both ends of a telescopic tube 7 of the support 1 (see FIGS. 1 and 10 ).
On the upper part of the telescopic tube 7 is arranged a three-cornered frame 8 that is constructed such that the upper side of the triangle is slanted upward. The free end of the frame 8 has a support 9 for a shaft 10 of a vertically swiveling arm 11 which has on a proximal end an adjustable fixed balance-weight 12 that turns the swivel-arm 11 into the upper at-rest position 11 that is defined by a catch 13 arranged on the frame 8 . The swivel-arm 11 can be set free by pulling a releasing cord 14 to disengage the catch 13 (see FIGS. 1, 8 and 9 )
On a distal end of the swivel-arm 11 , a ring 15 is fixed asymmetrically relative to the long axis of the swivel-arm to train the user with respect to tossing the ball during serve training. The ring 15 includes a suspension 16 for hanging a ball 17 in the desired hitting zone, which comprises two pieces of Velcro™ fastening 18 being hung on two threads 19 in such a way as to enable the ball to fly by hitting it with a tennis racquet 20 (see FIGS. 1 and 2 ).
According to FIG. 2, the position of the tennis player P relative to the ring 15 and correspondingly to the ball 17 and to a pulley 25 is defined by means of a pair of footprints 21 on a stepping plate M, which is placed on the ground 43 . On the stepping plate M are marked three pairs of footprints 21 , 21 a , 21 b with the base line markings 22 , 22 a , 22 b at different distances relative to a point F, which is the vertical projection of the ring center (see FIG. 1 ), to define the position of the player P depending upon the different kinds of serve (flat, slice, topspin serve).
According to FIGS. 1, 6 and 7 a stirrup 23 is fixed on the tennis racquet 20 , which is connected with a cord 24 that runs upwards to the pulley 25 fixed on the distal end of the swivel-arm 11 , through the pulley 25 , to a further pulley 26 fixed on the top of the telescopic tube 7 , and then downwards through a trigger mechanism 33 to a moveable releasing device 27 , which has a releasing pulley 28 . After turning around the pulley 28 , the cord 24 runs upwards along the tube 7 to an anchor point 29 .
On the tube 7 , between the frame 8 and the fixture 5 , vertically adjustable clamp 32 is arranged, which includes the trigger mechanism 33 fixed on a plate 34 . The trigger 35 turns on a stub axle 36 through a torsion spring 37 from a level position 35 f into a vertical position 35 v , which are defined or limited by a stop 38 (see FIGS. 1, 8 , 10 , 13 ).
In FIG. 8, the trigger 35 is shown in the working, level position 35 f being stopped on the stop 38 under the pressure of a bead 39 , which bead 39 is steadily clamped on the cord 24 at a certain distance from the anchor point 29 .
The pressure on the bead 39 is exercised through the cord 24 by means of an elastic rope 30 one end of which is fixed on the moveable releasing device 27 , then the elastic rope 30 runs through three pulleys 31 fixed on the lower and middle parts of the tube 7 to another moveable releasing device 70 (see FIGS. 1, 4 , 8 , 10 , 13 ).
The elastic rope 30 , being prestretched in the trigger position 35 f , exercises the towing force through the releasing device 27 only on the part of the cord between the bead 39 and the anchor point 29 .
The working level position of the trigger 35 f corresponds to the execution of the serve swing from a waiting stance of the player P A (shown on FIG. 1 as the racquet 20 A with a hand), through a position of the player P B (see FIG. 1) up to a lowest point of the loop of the serve swing, and through a position of the player P C (see FIG. 3 ).
Only at the lowest point of the loop, i.e. the position of the player P C (FIG. 3 ), the towing force will be activated overall on the cord 24 , correspondingly on the racquet 20 , by means of the plucking the cord 24 and moving the bead 39 shortly upwards to let the trigger 35 turn or move via the torsion spring 37 into the vertical position 35 v and move the bead 39 out of contact with a fork-like cutting 40 of the trigger 35 (see FIG. 13 ).
On FIG. 8 in large scale, the upper part of the support 1 is shown with the frame 8 , on which the catch 13 is arranged to fix the swivel-arm 11 in the upper attest position. A pin 41 fixed on the proximal end of the swivel-arm 11 will be automatically arrested with the catch 13 , this turns with a torsion spring 42 on an axle 45 . In the waiting stance, the catch 13 is stopped by means of a stop 44 (see FIG. 9 ).
The moveable releasing device 28 includes a carrying member 46 to fix the elastic rope 30 between two clamping screws 47 , an offset hinged folding-bracket 48 and a releasing mechanism 49 .
As shown on FIG. 13, the folding-bracket 48 is offset hinged relative to the cord 24 , on a joint-pin 50 in the carrying member 46 in order to provide the moment arm for secure folding out after releasing the stub axle 51 , bearing the turn-pulley 28 , out of the contact with two rotary latches 52 of the releasing mechanism 49 .
The rotary latches 52 with flange cheeks 53 turn on an axle 54 with a torsion spring 55 partly overlapping a hold 56 in the carrying member 46 and being in a groove 57 of the stub axle 51 in the closed position, which is defined by means of a stop 56 and a cutting 57 in the latches 52 (see FIGS. 12 and 15 ). The releasing port 58 is fixed on a vertically adjustable clamp 60 , which is placed on the down part of the tube 7 (see FIGS. 10, 11 and 13 ).
By entering into a releasing port 58 , the rotary latches 52 with flanged cheeks 53 will be turned through the contact with flanged cheeks 59 of the releasing port 58 letting the folding-bracket 48 fold out and thereby set the cord 24 free. After releasing the cord 24 , the releasing device 27 is stopped on a rubber shock absorber 61 , which is fixed on the releasing port 58 (see FIGS. 12, 13 and 15 ).
FIGS. 6 and 7 show the connection of the cord 24 with the tennis racquet 20 by means of the stirrup 23 , which is fixed on two flanges 62 , 63 bridging the grip of the tennis racquet 20 . The stirrup 23 includes a round rod 64 , an adjustable member 65 , protecting rubber rings 66 , and a glide ring 67 to connect the cord 24 .
The flanges 62 , 63 are clamped on the grip by means of two demountable yokes 68 . The form of the rod 64 , the adjustable member 65 and the glide ring 67 provide the shifting of the point of connection accordingly the point of the exerting of the towing force on the tennis racquet 20 , which is a necessary condition during the swing.
Although a particular preferred embodiment of the invention has been disclosed in detail for illustrative purposes, it will be recognized that variations or modifications of the disclosed apparatus, including the rearrangement of parts, lie within the scope of the present invention. | A training device which interactively guides a tennis racquet by exerting a towing force on a card which is connected to the tennis racquet. The device includes a vertically adjustable support connected with a guide pole fixed to a wall. A swivel arm is movably supported on the support and has a distal end which suspends a ball therefrom. The cord extends along the swivel arm and the support, and one end thereof is connected to the racquet through a stirrup. | 15,023 |
BACKGROUND OF THE INVENTION
The National Science Foundation provided funding used in part for this for this invention under grant RF 5311. Accordingly, the Federal Government may have certain rights in this invention pursuant to 35 U.S.C § 202.
1. Field of the Invention
The invention relates to an expression vector system based on the regulation of bacterial luminescence (the positive feedback lux regulatory circuit). The invention further relates to the construction of a precisely regulatable expression vector system which comprises a complete luxR gene in combination with an inactivated luxI gene, both of which are under the control of a common control region. The invention allows the precise temporal expression of gene products otherwise deleterious or lethal to the cell when controlled by standard expression systems. The invention further relates to the control of the expression system of the invention by an inexpensive inducer.
2. Description of the Related Art
Numerous expression systems exist for expression of gene products in bacteria. However, cloning and expression of genes which have deleterious effects on or which kill the cells in which they are expressed represents a continuing problem. Among these problem genes are a wide array of genes whose effects on the cell range from mildly deleterious to those gene products which are lethal to the cell in even minute quantities. As used herein, a deleterious gene is any gene whose expression in host cells in culture would prevent that culture from achieving the normal logarithmic growth which the culture would achieve but for the expression of the deleterious gene. Furthermore, as used herein, an expression system which is capable of stringently controlling the expression of such deleterious genes is an expression system which can sufficiently limit the expression of the deleterious gene in host cells in culture in order to allow the culture to achieve normal logarithmic growth which the culture would not achieve without the stringent control due to some level of transcription of the deleterious gene. Thus, in the case of genes whose products are lethal to the cell in even minute quantity, stringent control is that level of control which almost completely eliminates transcription of the lethal gene until released from that control.
Some deleterious genes encode gene products which if expressed in limited quantity are actually useful to the cell while if expressed in even slightly elevated quantities are deleterious to the cell. For example, such genes are epitomized by DNA-modifying enzymes such as the DNA restriction enzymes used throughout molecular biology. If allowed to be expressed in a host which is not resistant to the restriction enzyme, the host cell's own DNA is susceptible to degradation by the cloned gene's product (Rosenberg et al. 1981).
Even where a particular gene product merely stresses the host cell by its presence or by its overabundance, the production of these proteins in the cell may not be feasible. Such an effect has been observed, for instance, with overproduction of several of the subunits of E. coli RNA polymerase. Although it has been possible to overproduce the RNA polymerase subunits in host cells, their overexpression causes a reduction in growth rate of cultures of these cells (Bedwell and Nomura, 1986). These mildly deleterious effects represent enough of a stress to the population of cells that cells within that population, which contain a mutated version of the desired protein whose production has fewer or no deleterious effects compared to the non-mutated protein, may overgrow those cells containing the wild type protein.
Even more deleterious gene products include many proteins which become associated with the membrane of the host cells, some of which effect the cell to such a degree that the host cells are killed (Michaelis and Beckwith 1982). Some genes, in fact, code for proteins which, if expressed to any degree, even at levels as low as a few molecules of the protein per cell, lead quickly to the death of the host cell. These type of genes are typified by the class of genes encoding the lysis proteins of viruses (e.g., λ lysis protein or MS2 lysis protein) and the lytic proteins of bacteria (e.g., colicins of certain enteric bacteria) (Coleman et al. 1983; Adhya et al. 1971; Konisky 1982).
A number of patented expression systems for use in bacterial hosts have been described. In some cases, the expression systems relate to generalized expression systems. In others, specific positive regulation systems have been described. Other patented expression systems have been designed to allow relatively tight regulation. In some instances, these expression systems were individually tailored for expression of a particular protein which presented some difficulty using standard expression systems.
For instance, U.S. Pat. No. 4,782,022 appears to relate to the construction of a vector comprising a promoter of a constitutively expressed gene coupled to a gene which codes for a product capable of activating other genes required for nitrogen fixation. U.S. Pat. No. 4,775,630 appears to relate to a variant of an adenovirus control region, the regulator of which is especially sensitive to repression by products of the gene under its control. U.S. Pat. No. 4,767,708 appears to relate to the construction of a recombinant vector containing a cloned bacterial DNA polymerase I under operable control of a conditionally controllable foreign promoter. This patent notes that the foreign promoter may be a positively regulated promoter. The invention appears to be designed to overproduce DNA polymerase. U.S. Pat. No. 4,677,064 appears to relate to the use of the promoters of bacteriophage λ, P L and N RBS , in order to construct a vector capable of overexpressing human tumor necrosis factor. U.S. Pat. No. 4,634,678 appears to relate to construction of a variety of expression vectors all of which are based upon negative control systems. The patent's specification does, however, suggest the replacement of negative control sequences with positive control sequences. U.S. Pat. No. 4,578,355 appears to relate to the use of the P L promoter of bacteriophage λ to construct a high level expression vector. U.S. Pat. No. 4,503,142 appears to relate to the construction of a class of cloning and expression vectors capable of heterologous gene expression. These vectors are based on the use of the lac promoter/operator of Escherichia coli (E. coli).
All of these systems suffer, to greater or lesser degrees, from the inability to control expression to the extent required when the gene product will kill or otherwise seriously damage the host cell if expressed. The analogy can be drawn to an electrical switch connected functionally to a device capable of inflicting great harm to those which encounter it, even if the amount of electricity reaching the device is minimal. The design electrical engineer would find it most unsatisfactory if the only switches available were those which constantly fed the lethal device small amounts of power. Moreover, even where the prior art expression systems have provided a means for limited expression of certain deleterious genes, the likelihood that the gene will mutate in order to prevent the deleterious effects on the host cell from being realized has always caused concern. This is especially true where large scale operations have been envisioned.
Additionally, many of the prior art expression systems must rely for induction of expression either on the host's biochemical responses or on costly or awkward induction means. Moreover, many prior art expression systems suffer from the fact that the inducer is a compound routinely found in nature such as naturally occurring sugar compounds. Thus, great care must be taken to prevent inadvertent exposure of cells to extraneous sources of such commonly encountered inducers.
The present inventors are involved in research into regulation of bioluminescence in the marine bacterium Vibrio fischeri, which regulation has been studied extensively through cloning and genetic manipulation of the lux system in E. coli (Devine et al. 1989; Dunlap and Greenberg 1985; Dunlap and Greenberg 1988; Engebrecht et al. 1983; Engebrecht and Silverman 1984; Engebrecht and Silverman 1986). Expression of the lux genes in V. fischeri is controlled by a unique form of positive feedback regulation called autoinduction, and this pattern of regulation may be duplicated by the cloned system in E. coli (Engebrecht et al. 1983; Engebrecht and Silverman 1986). The autoinduction response is mediated by the production and accumulation of a small molecule, the autoinducer, which is synthesized in the presence of the luxI gene product. This product molecule presumably interacts with the luxR gene product to induce the synthesis of the enzymes required for light production. Kaplan and Greenberg (1987) were able to overproduce the luxR gene product in E. coli, develop a procedure for purifying this overproduced protein, but were unable to demonstrate convincingly that LuxR protein had DNA-binding activity.
The autoinducer of V. fischeri has been identified as N-(3-oxo-hexanoyl) homoserine lactone (Eberhard et al. 1981) and has been shown to be both freely diffusible across the cytoplasmic membrane and species specific in its ability to stimulate bioluminescence (Eberhard 1972; Kaplan and Greenberg 1985). This molecule has been synthesized in vitro and shown to function in a biological assay (Eberhard et al. 1981; Kaplan et al. 1985).
The lux genes are organized into two divergently transcribed operons, termed rightward and leftward, which are separated by a common regulatory region (Devine et al. 1988; Engrebrecht et al. 1983; Engebrecht and Silverman 1987). The luxR gene is the only known gene in the leftward operon (operon L ) and encodes a positive regulatory protein which, in the presence of autoinducer, stimulates transcription of the rightward operon (operon R ). This interaction has recently been shown to require the 20-base-pair lux operator located in the control region (Devine et al. 1989). Operon R consists of at least six genes (luxICDABE). The luxI gene encodes a protein required for autoinducer synthesis (Engebrecht and Silverman 1984), the luxC, luxD, and luxE genes encode enzymes which provide luciferase with an aldehyde substrate (Meighen 1988), and the luxA and luxB genes encode the α and β subunits of the luciferase enzyme. The sequence of the entire lux regulon from V. fisheri has been determined (Baldwin et al. 1989).
The current model describing the autoinduction process suggests that a low basal level of transcription of operon R leads to low-level synthesis of autoinducer by luxI. High cell density is required for autoinducer to accumulate, since it is freely diffusible across the cytoplasmic membrane. It is by virtue of the diffusible nature of autoinducer that the expression of luminescence is, in nature, cell density-dependent. If the LuxR protein, whose synthesis is regulated at the transcriptional level by the cyclic AMP-catabolite gene activator protein (cAMP-CAP) system (Dunlap and Greenberg 1985; Dunlap and Greenberg 1988), has also accumulated, it can form a complex with autoinducer capable of binding to the lux operator and stimulating transcription of operon R . Positive feedback results from the presence of luxI in operon R , since stimulation of rightward transcription of luxR and autoinducer leads to the production of more autoinducer by increased levels of LuxI protein. In addition to this primary regulatory circuit, several global regulatory systems in E. coli have been shown to interact with the lux system to affect the timing of induction of bioluminescence including the heat shock (σ 32 ) system and the SOS response (Ulitzur 1989; Ulitzer and Kuhn 1988). Thus, the positive feedback mechanism of the lux regulatory circuitry leads to the sharp induction of the enzymes required for light production.
Expression systems are needed which do not rely for their induction on expensive or otherwise inadequate induction mechanisms. This is especially important for commercial operation of bacterial fermentations of useful gene products. More importantly, however, expression systems are needed which are capable of very stringently regulating the expression of deleterious or lethal genes until such time as induction of expression can be used to express commercial quantities of their otherwise harmful gene products. If such systems were available, the expression and genetic manipulation of a wide array of otherwise lethal or deleterious gene products would be possible via the powerful capabilities of batch fermentation.
SUMMARY OF THE INVENTION
The present invention relates to an expression system capable of stringently regulating the expression of deleterious or lethal genes until such time as induction of expression can be used to express high levels of the harmful gene products. The present invention further relates to expression systems which need not rely for their induction on inadequate induction mechanisms which are typically bulky, expensive or both. The present invention, therefore, further relates to systems for the expression of a wide array of otherwise lethal or deleterious gene products using bacterial fermentation.
More specifically, the present invention relates to the construction of vectors which retain an intact luxR gene and regulatory region but which lack intact copies of all of the genes in operon R , retaining only a truncated luxI gene. This arrangement affords a very stringently regulated system in which operon R transcription is controlled by the addition of an inexpensive, synthetic inducer (autoinducer), but which system now lacks the positive-feedback mechanism. A potentially lethal transcriptional fusion of the lysis genes (S,R,R z ) from bacteriophage λ was created in operon R by insertion downstream of the truncated luxI gene in order to test the ability of this system to express a very lethal gene.
Such an expression system possesses two key attributes which distinguish the invention over the prior art. First, the transcription system of the invention is not as leaky as are those of the prior art. If the system is turned off, no significant transcription occurs of any cloned gene product when used in combination with the regulatory scheme of the invention. The surprising and unexpected level to which regulation can be controlled with this system was demonstrated convincingly by using the bacteriophage λ lysis genes. These bacteriophage lysis gene products are lethal to bacteria where even low transcription levels are allowed. Only a system which almost thoroughly stops transcription can be used to express such lethal proteins.
Coupled with the novel expression system, the second distinguishing attribute of the invention relates to the nature of the event which turns on transcription. The present inventors and others have found that other expression systems use either awkward or expensive events to stimulate synthesis of the cloned gene product. The stimulatory event of the present invention, however, relies on the addition of exogenous autoinducer which is both inexpensive and easy-to-use and which is required in only minute amounts. Additionally, this compound is not found routinely in nature avoiding problems of inadvertent induction found in prior art systems.
The present inventors set out to develop a flexible prokaryotic expression system utilizing the regulatory genes isolated from the marine bacterium Vibrio fischeri. The present inventors knew that V. fischeri displayed both a dramatic increase in the rate of luciferase synthesis following induction, apparently due to a unique positive feedback mechanism, and an enormous difference (ca. 10 5 ) in levels of luminescence in cells before and after induction. The present inventors have demonstrated that a 20 base pair inverted repeat, ACCTGTAGGA x TCGTACAGGT, is the binding site for the LuxR-autoinducer complex. They have also found that deletion of sequences upstream of the palindrome leads to increased transcription from the rightward promoter, indicative of a cis-acting element(s) that represses transcription in the absence of LuxR:autoinducer. Modifications of the palindrome that eliminate stimulation by LuxR:autoinducer of transcription from P R have no effect on repression by the cis-acting mechanism(s), suggesting that the palindrome is not necessary for repression of the rightward operon. Thus, it appears that the large increase in transcription upon induction of the lux regulon is the result of at least two independent mechanisms, one positive and the other negative. These unexpected findings lead to the realization that a unique system of expression might be possible which would allow a very stringent control of genes functionally connected to such an expression system.
The objective of the present inventors has been, therefore, to design and construct a unique vector in which induction is controlled by the addition of autoinducer. The requirement for autoinducer is accomplished by deletion of the luxI gene so that expression of the cloned gene can only be accomplished by addition of autoinducer. The basal level of rightward transcription is very low because the lux system is tightly repressed in the absence of autoinducer. This is an important consideration if the protein of interest is toxic to the host. Expression can be postponed until late in growth without adversely affecting the bacterium. This point was made very clear by the unexpectedly successful cloning and expression of the lysis genes from bacteriophage λ under control of operon R which allows control of cell lysis by autoinducer addition. In the absence of autoinducer, these lethal genes can be propagated without adversely affecting the host cells.
Accordingly, an expression system has been invented which consists of a lux regulatory circuit connected to and capable of stringently regulating expression of a gene. In a preferred embodiment of the present invention, at least one product of the cloned gene will be deleterious to the host cells used to express the gene. The deleterious effect may be one which directly occurs as a result of the presence of the gene product in the cell such as with a lysis protein. However, the deleterious effect may equally well be an indirect effect such as where membrane jamming occurs which eventually leads to the death of a cell.
The expression system may be used independent of other regulatory systems. Alternatively, one embodiment of the invention would include the use of the lux expression system operably linked to a second regulatory system or systems in order to achieve control of the second regulatory system by the lux expression system.
In this manner, the binding of the LuxR-autoinducer complex can also be adapted to perform a negative regulatory role. If the recognition sequence for LuxR-autoinducer is situated near a promoter such that its binding prevents the binding of RNA polymerase, then it becomes a repressor. Over two thousand-fold induction has been achieved with this strategy using lac repressor and its operator (Lanzer and Bujard 1988).
The lac system is controlled by inducers, usually isopropylthio-β-galactoside (IPTG) or allolactose, which, when bound to the lac repressor, reduce its affinity for the lac operator, thereby relieving repression. However, if LuxR were used as a repressor, its effector (autoinducer) would act as a co-repressor, much like L-tryptophan does with the trp repressor. The trp repressor-operator system can be "induced" if 3-β-indoleacrylic acid (IAA), a tryptophan analogue, is administered while sufficient L-tryptophan is present in the cell to cause repression (Joachimiak et al. 1983). The IAA competes with L-tryptophan for the trp repressor but the repressor-IAA complex does not bind tightly to the trp operator, so repression is relieved.
Eberhard and co-workers have synthesized autoinducer analogues and have shown several of these to be potent competitive inhibitors of autoinducer in Vibrio fischeri (Eberhard et al. 1986). It is possible that one or more of the analogues, like IAA with the trp repressor, could relieve repression by LuxR. If this approach proves impractical, relief of repression can be accomplished by harvesting the cells and resuspending them in fresh, autoinducer-free, culture medium.
The advantage of the LuxR "repressor" configuration is that one can make use of the specificity of LuxR for its economical, non-metabolizable effectors without relying on the specific protein-protein contacts between LuxR and prokaryotic RNA polymerases that are needed for transcriptional activation. Because only DNA binding is required of LuxR for repression, and because of the apparent permeability of membranes to autoinducer, this technology and its benefits could be extended to distantly related prokaryotic systems (e.g. gram-positive bacteria) and perhaps even to eukaryotic systems like yeast and cultured animal or plant cells.
In a highly preferred embodiment of the present invention, the lux regulatory circuit consists of a luxR gene derived from the operon L of a lux regulatory circuit. The luxR gene is under regulation of the control region of the lux regulatory circuit and operably linked to it. The lux control region is further connected to a portion of operon R . The rightward operon normally consists of intact and sequentially oriented genes, luxICDABE, but in this highly preferred embodiment the operon only retains a truncated luxI gene in order to disrupt the normal positive feedback associated with the rightward operon. The lux regulatory region of the present invention may be obtained from a number of different bioluminescent bacteria as will be well understood by those of skill in the art. In certain preferred embodiments, the lux regulatory circuit is isolated from Vibrio fischeri.
The expression system of the present invention is designed to allow expression of any deleterious gene products. However, in certain preferred embodiments the expression system may be used to express the product of a gene which, when expressed, is lethal to the host cell. Expression of a particularly lethal gene is provided in a preferred embodiment where lysis genes S, R and R z of bacteriophage λ are expressed using the expression system of the present invention. Similar genes would include the lysis genes of the MS2 virus and the lytic peptides of the enteric bacteria such as colicins.
Additionally, the expression system of the present invention is designed such that induction of expression is controlled by addition of an inducer to the environment of the host cells containing the expression system. Naturally occurring inducer may be used. In one embodiment, naturally occurring autoinducer produced endogenously within the host cell carrying the expression system of the present invention may be achieved as a function of the density of the host cells in culture. Since luxI, whose product is necessary for the synthesis of endogenously-produced autoinducer, is the first gene in operon R , LuxR stimulation leads to the synthesis of more autoinducer and a positive feedback loop is created leading to a sharp induction of operon R . The timing of induction is therefore a function of the basal level of rightward transcription, which determines the rate of initial accumulation of autoinducer. Vectors containing the intact luxR and luxI genes will allow the density-dependent regulation to be imposed on a target gene cloned downstream of luxI in operon R . The timing of induction can then be altered through mutagenesis of the rightward promoter, allowing variable basal levels of transcription to be achieved and induction of the target gene to occur at a chosen cell density.
However, in a preferred embodiment, the inducer will be an exogenously added inducer. In general and overall embodiments, the inducer must be able to induce the expression of the leftward operon to a degree adequate to initiate transcription in the rightward operon (See, e.g., Eberhard et al. 1986 for functional analogs). In a most preferred embodiment, the inducer will be the inexpensive and readily-synthesized molecule, N-(3-oxo-hexanoyl) homoserine lactone. In certain other embodiments, the inducer will be an autoinducer characterized as a small diffusible molecule capable of the requisite capability to control expression in combination with the regulatory circuits of the present invention.
It is, of course, possible to use the expression system of the present invention in the native Vibrio host or in related bacterial species. However, in a preferred embodiment, the expression system will be used in conjunction with Escherichia coli cells.
The present invention also relates to construction of vectors designed to carry lux regulatory circuitry associated with the expression systems of the invention. In a preferred construction, such vectors will contain a truncated luxI gene functionally connected to a multiple cloning site downstream of the truncated portion. Such multiple cloning sites are well known in the art and consist of a number of restriction endonuclease sites for ease of cloning gene-containing fragments downstream of the luxI truncation.
A method for expression of a deleterious gene is provided by the present invention as well. The steps include constructing a vector with a lux regulatory circuit, functionally connecting a deleterious gene to the lux regulatory circuit, transforming the vector containing the regulatory circuit and deleterious gene into a host cell and growing the resulting host cells to a late phase of growth in which there are many such cells with many such vectors and then inducing expression of the deleterious gene by adding an exogenous inducer to the growth medium of the bacterial culture.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1. Construction of the lysis vector pGS102. Small arrows indicate the 5'-to-3' direction of the gene indicated, and large arrows indicate cloning steps taken during the construction of the pGS102 plasmid (kb=Kilobases). Deletion of the DNA segment from SnaBI to BalI shown in pGS102 results in the preferred construction pGS103.
FIG. 2. Growth of cultures of E. coli TB1 carrying the plasmid pGS103 and demonstration of autoinducer-dependent cell lysis. Autoinducer (5 μM) was added from the beginning of the experiment where indicated.
FIG. 3. Autoinducer response of pJHD500 and three LuxR - pJHD500 derivatives, Symbols: and o, pJHD500-wild type LuxR; , H127Y; , V82L; , V821. Open symbols indicate no autoinducer added to the culture, and closed symbols indicate the addition of 2.5 μM autoinducer from the beginning of the experiment.
FIG. 4. Critical regions of the LuxR protein defined by random mutagenesis and the primary sequence of the autoinducer-binding region ( ). Boldface type indicates random mutations isolated in this study which map between residues 79 and 127. Open type indicates random mutations isolated by Slock et al. (1990) which map between residues 79 and 127. Letters in parentheses indicate amino acid changes introduced by site-directed mutagenesis. The second critical region is defined by mutations isolated by Slock, et al. (1990) and the H217Y mutation isolated in this study ( ).
DESCRIPTION OF PREFERRED EMBODIMENTS
The following examples describe, in detail, the steps required to practice the present invention and demonstrate the utility of the expression system of the present invention when used in combination with a very lethal gene product, the lysis genes of λ bacteriophage. In particular, the construction of a plasmid vector which retains an intact luxR gene and regulatory region but lacks all of the genes in the operon R , retaining only a truncated luxI gene is described. This arrangement resulted in an expression system in which operon R transcription is controlled by the addition of synthetic autoinducer but which lacks the positive-feedback mechanism. The potentially lethal transcriptional fusion of the lysis genes (S,R,R z ) from bacteriophage λ was created in operon R by insertion downstream of the truncated luxI gene demonstrating the utility of the invention for the expression of a very lethal lytic gene product. In another demonstration of the utility of the present invention, vector (pGS102) was used in a lethal genetic selection in conjunction with a subsequent luminescence screen to recover point mutations in the luxR gene.
EXAMPLE I
Enzymes and chemicals. Restriction enzymes and T4 DNA ligase were purchased from New England Biolabs, Inc., or Boehringer Mannheim Biochemicals. Klenow fragment of E. coli DNA polymerase I and modified T7 DNA polymerase (Sequenase) were purchased from United States Biochemicals. ATP and deoxyribonucleotides were obtained from Pharmacia LKB. Radiolabeled dATP was obtained from Dupont, NEN Research Products. Hydroxylamine hydrochloride and n-decanal were obtained from Sigma Chemical Co. All other chemicals were of the highest quality commercially available.
Cell strains. All growth experiments were performed using E. coli TB1 [hsdR Δ(lac pro)]. E. coli CA8404 (crp* was a gift of Pete Greenberg, but is readily obtainable by methods known well to those of skill in the art) was used to achieve better complementation with luxR in trans. This strain produces a mutant CAP which does not require cAMP to activate transcription from cAMP-CAP-regulated promoters.
Plasmid constructions. Construction of the lysis vector pGS102 is summarized in FIG. 1. pGS102 was constructed from the plasmid pSB101, which contains a BglII restriction fragment harboring the bioluminescence genes luxR, -I, -C, and -D' cloned into the BamHI site of pBR322 with the transcription of operon R oriented opposite that of the tet gene. To eliminate production of the autoinducer via the luxI gene product, pSB101 was digested with ClaI, filled with Klenow fragment, partially digested with HincII, and ligated to yield plasmid pSB103 containing a truncated luxI gene fused at the ClaI site of pSB101. The lysis genes of bacteriophage λ (S, R, and R z ) were isolated on a 1.5-kilobase EcoRI restriction fragment from plasmid pSRI, which is a derivative of plasmid pRGI (Raab et al. 1986) with the unique HindIII site converted to an EcoRI site by using synthetic adapters. This EcoRI fragment was subsequently ligated into the EcoRI site of pSB103 to yield pGS102. Restriction analysis was used to screen for the proper orientation of the lysis genes in the pGS102 construction which generated a transcriptional fusion between operon R of the V. fischeri lux genes and the λ lysis genes, which were now located downstream of the truncated luxI gene.
A SnaBI-BalI deletion of pGS102 was constructed to remove V. fischeri DNA that was downstream of the luxR gene in the operon L . This construction was called pGS103 and exhibited the same lysis phenotype as pGS102.
The construction of plasmid pJHD500 has been described earlier (Devine et al. 1989). This plasmid is similar to pGS102, except the lux A and luxB genes, encoding the subunits for the luciferase enzyme from Vibrio harveyi, were cloned downstream of the truncated luxI gene, creating a bioluminescent transcriptional reporter for operon R . DNA containing mutations in the luxR gene generated in pGS102 and pGS103 were subcloned into pJHD500 in order to quantitate the ability of the mutant LuxR proteins to stimulate rightward transcription.
Growth of cultures and measurement of the Extent of Cell Lysis. The ability of the mutant LuxR proteins to respond to autoinducer was determined by monitoring cell growth and aldehyde-stimulatable luminescence of samples withdrawn from cultures grown in 50-ml culture flasks containing (initially) 12 ml of Luria-Bertani (LB) medium with carbenicillin (100 μg/ml) at 30° C. in a New Brunswick model G76 gyratory water bath shaker at 200 rpm. Inoculation was from overnight cultures grown at 30° C. and diluted 1/200 (vol/vol). Samples (1 ml) were removed at various times during growth. Cell density was determined as the optical density at 600 nm (OD 600 ) by using a Milton Roy Spectronic 601 spectrophotometer. The same samples were then used for luminescence measurements in vivo by transferring the sample into a 20-ml scintillation vial, placing the vial in a photometer, and injecting 1 ml of a sonicated solution of n-decanal (10 μl of aldehyde per 10 ml of LB medium). Peak light emission was monitored by using a photomultiplier-photometer for which 1 light unit represents 9.8×10 9 quanta/s, based on the liquid light standard of Hastings and Weber (1963).
Data depicting cell lysis were collected by monitoring culture growth in 125-ml culture flasks containing 20 ml of LB medium with carbenicillin (100 μg/ml) at 30° C. in a New Brunswick Aquatherm water bath with shaking at 100 rpm. Duplicate cultures were inoculated by dilution (1/200 [vol/vol]) of an overnight culture grown at 30° C. with an additional of autoinducer of one of the cultures immediately after inoculation. Cell lysis was detected as a drop in the OD 600 of the culture.
Pure autoinducer was synthesized by the method of Eberhard et al. (Eberhard et al. 1981) and was stored as a 50 mM solution in water at 4° C. This stock was further diluted into the growth medium to the desired concentration. The concentration of autoinducer was calculated by using the weight of the dried, purified material and a molecular mass of 213 g/mol for autoinducer.
Colonies containing pJHD500 and its luxR mutant derivatives were screened for luminescence on solid medium by applying n-decanal to the lid of a petri dish and observing the glowing colonies in a dark room.
It is important to note that certain problems were encountered in this study while adapting the lysis method to the lux system which were mainly a result of different temperature requirements for the lux system isolated from a marine bacterium, and the lysis genes which normally function in the enteric bacterium E. coli. For example, when E. coli carrying a lysis plasmid was grown at 37° C., cell lysis was observed in the absence of autoinducer. However, cell lysis was not observed in the absence of autoinducer when the cultures were grown at 30° C. or lower. This apparently resulted from either an increased basal level of transcription of operon R at 37° C. or the ability of the protein products of lysis genes to function more efficiently at the higher temperatures. Temperature therefore appears to be one parameter which can be adjusted to optimize the conditions for the lysis selection and may provide a means for controlling the lethality of the lysis genes, allowing selection of a variety of mutants.
Mutant selection in liquid medium. A variety of growth conditions were used for lysis selection in liquid medium. Temperatures were varied between 24° and 37° C., and M9 minimal medium supplemented with glycerol (0.2%), proline (40 μg/ml), and thiamine (0.001%) was used as well as LB medium. Autoinducer concentrations were varied between 0.5 and 5 μM. In all experiments, 5-ml cultures of E. coli TB1 containing plasmid pGS102, prepared by inoculation from overnight cultures by dilution (1/100) into medium containing carbenicillin (100 μg/ml), were used. Duplicate cultures were incubated with and without autoinducer until cell lysis was observed visually as a loss of the turbidity of the culture. Cultures were then diluted into fresh medium, plated onto solid LB medium, and incubated at 30° C. to allow growth of surviving cells. In some cases, the lysed cultures were pelleted, resuspended in fresh autoinducer-containing medium, and taken through a second lysis induction (double-induction experiment).
Hydroxylamine mutagenesis and screening on solid medium. Hydroxylamine mutagenesis was done essentially as described previously (Humphreys et al. 1976). Purified pGS103 (2.5 μg) was suspended in 250 μl of a 1M hydroxylamine solution at pH 6.0. The hydroxylamine solution was prepared by mixing 125 μl each of a 2M hydroxylamine solution (0.7 g of hydroxylamine hydrochloride dissolved in 0.56 ml of 4N NaOH and adjusted to 5 ml with sterile water) and a 2×TE solution (200 mM Tris Cl, pH 6.0, 2 mM EDTA). This mutagenesis mixture was incubated at 65° C. for 35 min, and the modified DNA was precipitated with 2 volumes of ethanol after the addition of ammonium acetate to 1M. The pellet was suspended in TE (pH 8.0), and 0.25 μg was used to transform competent E. coli TB1. Transformed cells were plated in duplicate onto solid LB medium containing carbenicillin (100 μg/ml) with and without 5 μM autoinducer. Mutant colonies were screened as normal opaque colonies on autoinducer-containing plates against a background of translucent colonies (see, Example II, infra).
DNA sequencing. Double-stranded plasmid DNA was prepared from overnight cultures by the alkaline lysis method (Maniatis et al. 1982). The DNA pellets were then treated with RNase A and precipitated with polyethylene glycol 8000. The purified DNA was then denatured with NaOH and used as template for sequencing by the dideoxy-chain termination method using modified T7 DNA polymerase (Sequenase) (Tabor and Richardson 1987). Sequencing primers used to sequence luxR have been described elsewhere (Devine et al. 1989).
Site-directed mutagenesis. Site-directed mutagenesis was done by the method of Kunkel et al. (1987), with slight variations. Single-stranded uracil-containing DNA isolated from phagemid-infected cells was used as a template for the mutagenesis reactions. Purification of the template was done as described earlier (Devine et al. 1989), except the starting plasmid was pVFS185, which is a derivative of pTZ18R (Pharmacia) containing a SacI restriction fragment harboring most of luxR, all of luxI and luxC, and a portion of luxD.
EXAMPLE II
Demonstration that the lysis phenotype is under lux control. The lysis vectors pGS102 and pGS103 both allowed expression of the lysis phenotype to be controlled by the addition of synthetic autoinducer. A SnaBI-BalI deletion of pGS102 was done to create pGS103 (FIG. 1). The deleted sequences consisted of uncharacterized V. fischeri DNA and a portion of the pBR322 vector. Removal of these sequences had no effect on the induction of cell lysis by the addition of autoinducer. A Budapest Treaty Deposit was made prior to the filing of the present patent application with the United States Patent and Trademark Office to the American Type Culture Collection of pGS103 and that deposit has been assigned accession number ATCC 40830.
When autoinducer was added from the beginning of the growth experience or at an early point in growth, a lag was observed prior to cell lysis while LuxR protein accumulated. A typical lysis curve is shown in FIG. 2. At 30° C. in LB medium, with autoinducer added at the beginning of the experiment, cell lysis was observed as a decrease in the OD 600 of the culture between 4.5 and 5 h after initial inoculation of the culture (OD 600 , 1.2), followed by a steady decrease in OD 600 during the next several hours. When autoinducer was added at a later point during culture growth, the lag period was decreased. The lag could be almost completely eliminated if E. coli CRP* was used, since the stimulation of luxR expression by cAMP-CAP does not require the accumulation of cAMP in this strain (data not shown). These observations suggest that the timing of induction was mainly a function of the cAMp-CAp stimulation of luxR expression.
Selection of mutants following lysis induction in liquid medium. Selection of lux regulatory mutants was accomplished by the addition of autoinducer to cultures grown in liquid medium at 24° C. and allowing the culture to incubate overnight (12 to 14 h) with shaking. Cells surviving the lysis induction were then grown on solid medium. Two problems were encountered with this procedure. First, a background of colonies was observed which retained the ability to lyse when screened in liquid medium for a nonlysing phenotype. Second, a considerable proportion of the colonies isolated from the selection which did retain a nonlysing phenotype carried plasmids which had suffered deletions and/or other rearrangements of the original pGS102 plasmid. The former problem was partially eliminated by pelleting the cells from the initial lysis induction, suspending them in fresh autoinducer-containing medium, and taking them through a second lysis induction under identical conditions. Dilutions plated from these cultures exhibited a lower background of surviving nonmutant colonies.
From the double-induction experiment in M9 medium at 24° C., 18 colonies, which were presumably mutant, were picked and grown overnight to isolate of plasmid DNA and to screen for a nonlysing phenotype in liquid medium. All 18 mutants exhibited a nonlysing phenotype, and 13 of these 18 isolates had wild-type restrictions patterns for the pGS102 plasmid. To screen for mutations which were not plasmid-borne, the plasmid DNA from the remaining 13 mutants was retransformed into wild-type E. coli and again screened for lysis in response to autoinducer in liquid medium. By this criterion, six of these mutants (L2S2, L2S9, L2S14, L2S18, L2S20, and L2S21) were results of non-plasmid borne mutations and were probably results of E. coli chromosomal mutations which prevented cell lysis. The remaining seven mutants were judged to be plasmid borne and were next screened for luxR null phenotypes by checking for lysis in the presence of autoinducer with luxR supplied in trans on a compatible plasmid (pAC102). All seven of the mutants (L2S3, L2S5, L2S7, L2S8, L2S10, L2S15, and L2S17) exhibited a luxR null phenotype. The nucleotide sequences of the luxR genes from the luxR null mutants were determined, and the results are shown in Table 1. No mutation was identified within the luxR coding region for the L2S10 and L2S15 isolates.
TABLE 1______________________________________Summary of luxR point mutations isolatedby variations of the lysis selection luxRMutation nucleotide LuxR amino Lysisdesignation change.sup.a acid change selection.sup.b______________________________________L2S3 T-114 to A C-38 to TGA (stop) LL2S5 G-325 to T V109L LL2S7 G-368 to T S123I LL2S8 G-352 to T L118F LL2S17 T-502 to G Y-169 to TAG (stop) L C-508 to A R170R (silent)XS-2 G-244 to A V82I SXS-3 C-649 to T H217Y SXS-4 G-235 to A D79N S______________________________________ .sup.a Positions are numbered from 1 starting with the A of the AUG start codon for luxR indicated by Devine et al. (1988). .sup.b L, Lysis selection in liquid medium; S, lysis screen on solid medium after hydroxylamine mutagenesis (see, Example I, supra).
Hydroxylamine mutagenesis and lysis screen on solid medium. Attempts to select mutants by the lysis technique on autoinducer containing solid medium resulted, as with the liquid medium selection, in a large background of colonies which retained a lysing phenotype when screened in liquid medium. The desired mutant colonies could, however, be discriminated from the background of surviving nonmutant colonies as a normal versus translucent phenotype. The translucent phenotype was presumably due to a heterogeneous population of lysed and unlysed cells. In order to increase the frequency of mutant colonies, the plasmid pGS103 was modified by reaction with hydroxylamine in vitro prior to screening for mutants on autoinducer-containing solid medium. By this method, approximately 15% of the colonies were of the mutant phenotype in the hydroxylamine experiment, whereas in the control experiment of unmodified plasmid, mutant colonies were observed only at very low frequencies. Twenty mutant colonies were isolated with this screen, and plasmid DNA was prepared for further study.
Quantitation of autoinducer response of luxR point mutations. To recover mutations of the luxR gene, restriction fragments containing portions of the luxR gene from the 20 mutants isolated by the hydroxylamine experiment described above were subcloned into the bioluminescent rightward reporter vector pJHD500 and screened as dim colonies on autoinducer-containing solid medium. Colonies of cells containing pJHD500 with a wild-type luxR were bright under these conditions. Eight dim mutants were picked from this screen, five of which possessed a wild-type restriction pattern, indicating an intact luxR gene. Three of these were sequenced and shown to contain point mutations in luxR resulting in changes in the LuxR amino acid sequence of Val at position 82 to Ile, hereinafter designated as V821, H217Y, and D79N (Table 1). In addition, the three missense mutations and the L2S3 nonsense mutation isolated by the liquid lysis induction were subcloned into pJHD500 to allow transcription from operon R to be measured. To screen for mutations which could respond to higher concentrations of autoinducer, cells containing the luxR mutant derivatives of pJHD500 were replica plated onto solid medium with and without 5 μM autoinducer. The LuxR protein with the amino acid change of V821 was the only mutant observed by a visual screen to respond to this (elevated) concentration of autoinducer. To further examine the autoinducer response of the change at position 82, a second mutation was introduced by site-directed mutagenesis which changed the valine at this position to leucine instead of isoleucine.
A similar genetic study of the LuxR protein from V. fischeri MJ1 has been reported by Slock et al. (1990). These authors describe the isolation of several LuxR missense mutations, one of which was observed to respond to higher concentrations of autoinducer. This mutation resulted in the replacement of the histidine at position 127 with tyrosine. In order to quantitate the autoinducer response of this mutation with out reporter vector, the same mutation was constructed by site-directed mutagenesis and subcloned into pJHD500. The change was introduced by site-directed mutagenesis rather than by subcloning of the Slock et al. (1990) mutation because of the two different strains of V. fischeri which were used (ATCC 7744 and MJ1) and which have been shown to have differences in the amino acid sequence at four positions within the LuxR protein (Devine et al. 1989). Thus, the present inventors wanted to ensure that the observed phenotype was the result of the change at position 127 and not due to strain differences in the LuxR protein.
Growth curves and luciferase assays in vivo were done for the total of nine luxR mutations cloned in the reporter vector pJHD500. The autoinducer response was measured as the ability of the mutations to stimulate operon R transcription in the presence of autoinducer (2.5 μM) above the basal level observed in the absence of autoinducer. The results are summarized in Table 2, and complete growth curves of those mutations which respond to autoinducer are shown in FIG. 3. The results presented in FIG. 3 and Table 2 demonstrate that the change of V821 responded with an activity of approximately 70% that of the wild-type protein (23-versus 33-fold stimulation above the basal level at an OD 600 of 1.5). The site-directed changes of V82L and H127Y responded to a much lower extent, giving only 8 and 6% of the stimulation of the wild-type protein, respectively. The change of D79N was observed to reproducibly give stimulation of about 1% that of the wild-type protein at a 10 -fold-higher autoinducer concentration than that used in the above experiments (data not shown). Both of the position 82 mutants, as well as the H127Y mutant, were screened for response to a range of autoinducer concentrations. With all three of these variants, it was found that elevated levels of autoinducer were required to compensate for the lesion (data not shown). None of the remaining mutations exhibited significant autoinducer-dependent stimulation (Table 2).
TABLE 2______________________________________Autoinducer response of luxR point mutationsmeasured in the transcriptional reporter vector pJHD500Light units/ml.sup.aLuxR Withvariant of Without autoinducer Stimulation %pJHD500 autoinducer (2.5 μM) (fold) Stimulation______________________________________pJHD500 8.0 265 33 100L2S3 9.0 9.0 None 0D79N 9.0 10.0 None .sup. 0.sup.cV82I 7.5 175 23 70V82L 8.0 20.0 2.5 8V109L 7.0 8.0 None 0L118F 8.0 8.0 None 0S123I 6.5 6.0 None 0H127Y 8.0 15.0 1.9 6H217Yd 2.0 2.3 None 0______________________________________ .sup.a Peak light emission measured from 1 ml of culture at an OC.sub.600 of 1.5. .sup.b Values are given relative to the stimulation achieved by the wildtype LuxR protein encoded by the pJHD500 construction. .sup.c At a 10fold-higher autoinducer concentration, the response of D79N is about 1% that of the wildtype protein. .sup.d The H217Y data were collected during a different growth experiment under a different set of conditions than was used for the other mutations shown in Table 1 (100 rpm, 29° C., 2.5 μM autoinducer).
Location of random mutations in luxR. The locations of the randomly generated mutations isolated in this study are shown in FIG. 4 along with two mutations isolated by Slock et al. (1990), G121R and H127Y, which reside in the same region of the LuxR primary sequence. A total of seven randomly generated missense mutations occur within a 49-amino-acid stretch of the LuxR protein spanning residues 79 to 127 labeled as the autoinducer-binding region in FIG. 4 (see, Example III, infra). One mutation isolated during the luminescence screen, H217Y, occurred within a second critical region in LuxR spanning residues 184 to 230 and defined primarily by mutations isolated by Slock et al. (1990) (FIG. 4).
EXAMPLE III
Several features of the lysis gene cassette from bacteriophage λ make it generally useful as the lethal component in a lethal genetic selection. The results of an exhaustive mutational analysis of the bacteriophage λ S gene revealed that host mutations which confer resistance to the lethal action of the S protein are not recovered, since the S protein apparently acts alone in forming the lethal pore in the cytoplasmic membrane (Raab et al. 1986). This is not true for many other lethal proteins, which require interaction with host components in order to exert their lethal functions. The S gene is the only lethal gene of the three comprising the lysis cassette, and it consists of only 107 codons. The small size of the S gene makes it a small target for mutation, and therefore, the frequency of recovering mutations in the lysis cassette which prevent lethality is very low. In addition, many of the codons constituting the S gene are not mutable by transitions to "knockout" missense mutations or non-sense mutations which result in loss of S protein function. Lastly, a simple secondary screen can distinguish between the desired transcriptional control mutants and unwanted S gene mutants. This screen utilizes the ability of a limited amount of chloroform to substitute for S protein pore formation by disrupting the cell membrane and allowing the diffusion of accumulated murein transglycosylase into the periplasm (Goldberg and Howe 1969). The murein transglycosylase, the product of the λ R gene, is responsible for degradation of the peptidoglycan in the E. coli cell wall (Bienkowska-Szewczyk et al. 1981). Transglycosylase accumulation does not require S gene function; therefore, mutations which decrease transcription of the lysis cassette will not lyse even in the presence of chloroform, while mutations in the S gene will allow lysis in the presence of chloroform since the transglycosylase can still accumulate and is free to enter the periplasm.
In this study, the λ lysis cassette was used to isolate mutations in the luxR gene from V. fischeri with E. coli as a host for the cloned lux genes. A transcriptional fusion was created between the bacteriophage λ lysis genes and operon R by insertion downstream of a truncated luxI gene. The resulting plasmid allowed cell lysis to be controlled by the addition of synthetic autoinducer to the growth medium. Mutations in the luxR gene generated by variations of this lysis selection were subcloned into the luminescent reporter vector pJHD500, which created both a secondary screen for defective LuxR proteins and a method for quantitating the ability of these LuxR variants to respond to autoinducer.
A total of seven randomly generated missense mutations have been characterized, and by DNA sequence analysis, the lesions have been shown to occur within a 49-amino-acid stretch of the LuxR primary sequence. An additional mutation introduced by site-directed mutagenesis changed the valine at position 82 to leucine. A change of valine to isoleucine at position 82 of LuxR resulted in a protein with 70% of the autoinducer-dependent transcriptional stimulation capacity of the wild-type protein, while changing this same valine to a leucine resulted in a protein exhibiting only 8% of the wild-type response (Table 2). The ability of such conservative changes at position 82 of LuxR, valine to isoleucine and valine to leucine, to dramatically affect the autoinducer response of the resulting proteins suggests that this residue may be involved in direct interaction with the autoinducer molecule. A total of four luxR mutations yielded proteins which exhibited an ability to stimulate transcription of operon R , albeit to lower-than-wild-type levels, while the remaining luxR mutations did not allow any detectable autoinducer-dependent stimulation, even at elevated concentrations of autoinducer. The clustering of the seven randomly generated mutations within the region spanning residues 79 to 127 of the LuxR protein demonstrates that this region of the protein is critical for activity. The ability of several mutations within this region to respond to elevated concentrations of autoinducer suggests that the autoinducer-binding site is composed, at least in part, of amino acids residing within this region.
The possibility that the mutations in the proposed autoinducer-binding region may result in the production of unstable proteins which could give rise to the defective autoinducer response phenotype observed cannot be ruled out by the data of the present invention. However, two additional mutations isolated by Slock et al. (1990), G121R and H127Y, were shown by Western immunoblot analysis to be synthesized in vivo at levels comparable to those of the wild-type protein. These results increase the likelihood that the mutant proteins of the present invention are likewise produced at wild-type levels. This is especially true of the mutations at position 82 of luxR which both give stimulation greater than does the H127Y protein, which is synthesized at wild-type levels. It is difficult to imagine a situation in which the proteins with position 82 mutations could give greater stimulation if they were synthesized at levels lower than wild-type levels.
The results of this mutational study of the LuxR protein, coupled with those of Slock et al. (1990), demonstrate that at least two functional regions exist in the LuxR protein. One region spans amino acids 79 to 127 and is proposed to be an autoinducer-binding region, and the other region spans amino acids 184 to 230 (FIG. 4). Although no experimental evidence demonstrates that the mutations isolated by Slock et al. (1990) and the mutation of H217Y isolated in this study, which resides in this second critical region, are in fact defective in DNA binding, there is some recent evidence which supports the hypothesis that a carboxy-terminal DNA-binding region exists in LuxR. Alignment of amino acid sequences similar to those of the LuxR protein by Henikoff et al. (1990) revealed that a carboxy-terminal region of LuxR has a sequence similar to regions within nine other diverse bacterial proteins, including five known activator proteins (FixJ from Rhizobium meliloti, MalT and UhpA from E. coli, GerE from Bacillus subtilis, and RcsA from Klebsiella aerogenes). The apparently homologous regions revealed have been predicted to form a helix-turn-helix DNA-binding motif at a common position which includes residues within the region defined by mutations residing between positions 184 and 230 in LuxR. Further biochemical evidence is required, however, before this region can be unequivocally defined as the DNA-binding region of the LuxR protein.
The primary regulatory circuit controlling the induction of bioluminescence in V. fischeri appears to require three interacting elements: the LuxR protein, the autoinducer molecule, and the lux operator. Early genetic studies in which lux regulatory functions were deleted by transposon insertion mutagenesis demonstrated that the luxR and luxI genes were both required for the proper induction of bioluminescence (Engebrecht et al. 1983). Insertions in luxR resulted in loss of a function which could not be recovered by the addition of autoinducer, whereas insertions in the luxI gene were complemented by autoinducer addition. These observations led to a model which suggested that the luxI gene product was required for autoinducer synthesis and that the luxR gene product interacted with the autoinducer molecule to stimulate transcription of operon R . Recent studies supported that model and demonstrated that a 20-base-pair palindrome, the lux operator, located within the control region is also required for autoinducer-dependent stimulation of transcription of operon R (Devine et al 1989). Several mutations in the luxR gene which encoded variant LuxR proteins with altered autoinducer responses have been isolated in this manner. Demonstration that these mutant proteins can respond to higher concentrations of autoinducer provide the first evidence supporting the direct interaction between LuxR and autoinducer (Shadel et al. 1990).
REFERENCES CITED
The following references to the extent that they provide procedural details supplementary to those set forth herein, are specifically incorporated herein by reference.
1. Adhya, et al. 1971. pp. 743-746, The Role of Gene S. In, P. R. Hershey, (ed.), The Bacteriophage Lambda. Cold Spring Harbor Laboratory, Cold Spring Harbor, N.Y.
2. Baldwin et al. 1989. J. Biolumin. Chemilumin. 4:326-341.
3. Bedwell and Nomura. 1986. Mol. Gen. Genet. 204:17-23.
4. Bienkowska-Szewczyk, et al. 1981. Mol. Gen. Genet. 184:1112-1114.
5. Coleman, et al. 1983. J. Bacteriol. 153:1098-1110.
6. Devine, et al. 1988. Biochemistry 27:837-842.
7. Devine, et al. 1989. Proc. Natl. Acad. Sci USA 86:5688-5692.
8. Dunlap and Greenberg. 1985. J. Bacteriol. 164:45-50.
9. Dunlap and Greenberg. 1988. J. Bacteriol. 170:4040-4046.
10. Eberhard. 1972. Bacteriol. 109:1101-1105.
11. Eberhard, et al. 1981. Biochemistry 20:2444-2449.
12. Eberhard, et al. 1986. Arch. Microbiol. 146:35-40.
13. Engebrecht, et al. 1983. Cell 32: 773-781.
14. Engebrecht and Silverman. 1984. Proc. Natl. Acad. Sci. USA 81:4154-4158.
15. Engebrecht and Silverman. 1986. Regulation of expression of bacterial genes for bioluminescence, p. 31-44, In J. K. Setlow and A. Hollaender (eds.), Genetic Engineering, vol. 8. Plenum Publishing Corp., New York.
16. Engebrecht and Silverman. 1987. Nucleic Acids Res. 15:10455-10467.
17. Goldberg and Howe. 1969. Virology 38:200-202.
18. Hastings and Weber. 1963. J. Opt. Soc. Am. 53:1410-1415.
19. Henikoff et al 1990. Methods Enzymol 183:111-132.
20. Humphreys, et al. 1976. Mol. Gen. Genet. 145:101-108.
21. Joachimiak, et al. 1983. Proc. Natl. Acad. Sci. USA 80:668-672.
22. Kaplan, et al. 1985. J. Labelled Compd. Radiopharm. 22:387-395.
23. Kaplan and Greenberg. 1985. J. Bacteriol. 163:1210-1214.
24. Kaplan and Greenberg. 1987. Proc. Natl. Acad. Sci. USA 84:6639-6643.
25. Konisky. 1982. Ann. Rev. Microbiol. 36:125-144.
26. Kunkel, et al. 1987. Methods Enzymol. 154:1367-1382.
27. Lanzer and Bujard. 1988. Proc. Natl. Acad. Sci. USA 85:8973-8977.
28. Maniatis, et al. 1982. Molecular cloning: a laboratory manual. Cold Spring Harbor Laboratory, Cold Spring Harbor, N.Y.
29. Meighen. 1988. Ann. Rev. Microbiol. 42:151-176.
30. Michaelis and Beckwith. 1982. Ann. Rev. Microbiol. 36:435.
31. Raab, et al. 1986. J. Bacteriol. 167:1035-1041.
32. Rosenberg, et al. 1981. pp. 132-164. In, J. G. Chirikjian (ed.), Gene Amplification and Analysis.
33. Shadel, et al. 1990. J. Bacteriol. 172:3980-3987.
34. Slock, et al. 1990. J. Bacteriol. 172:3974-3979.
35. Tabor and Richardson. 1987. Proc. Natl. Acad. Sci. USA 84:4767-4771.
36. Ulitzur. 1989. J. Biolumin. Chemilumin. 4:317-325.
37. Ulitzer and Kuhn. 1988. J. Biolumin. Chemilumin. 2:81-93.
The present invention has been described in terms of particular embodiments found or proposed to comprise preferred modes for the practice of the invention. It will be appreciated by those of skill in the art that, in light of the present disclosure, numerous modifications and changes can be made in the particular embodiments exemplified without departing from the intended scope of the invention.
For example, those of skill in the art will appreciate that it is possible to utilize the expression system, vectors and methods of the present invention to express genes whose products vary in their degree of toxicity to the cells in which they reside. Additionally, the regulatory circuitry that is the subject of this invention may be used directly to regulate gene expression or it may be used in an indirect manner by serving as a controlling element in combination with one or more secondary regulatory systems. In a similar manner, the expression systems, vectors and methods of the present invention may rely on induction of gene expression by addition of exogenously added inducer or may rely on endogenous autoinducer. All such modifications are intended to be included within the scope of the appended claims. | The invention relates to an expression vector system based on the regulation of bacterial luminescence (the lux gene system). The invention further relates to the construction of a precisely regulatable expression vector system which comprises a complete luxR gene in combination with an inactivated luxI gene. If the system is turned off, no significant transcription occurs of any cloned gene product when used in combination with the regulatory scheme of the invention as is demonstrated by using the bacteriophage λ lysis genes. The induction of transcription relies on the addition of exogenous autoinducer which is both inexpensive and easy-to-use and which is required in only minute amounts. | 63,392 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a national phase application based on PCT/EP2003/010812, filed Sep. 30, 2003, the content of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a cable with a coating layer made from a waste material.
More particularly, the present invention relates to a cable including at least one core comprising at least one transmissive element and at least one coating layer, said coating layer being made from a coating material comprising at least one polyethylene obtained from a waste material.
Moreover, the present invention relates to a process for producing said cable.
For the purposes of the present description and of the subsequent claims, the term “core” of a cable is used to indicate a semi-finished structure comprising a transmissive element, such as an electrical energy transmissive element, an optical signal transmissive element or an element which both transmits both electrical energy and optical signals, and at least one electrical isolation or, respectively, at least one containment element (such as, for example, a tube, a sheath, a microsheath or a grooved core), or at least two elements, one of which is an electrical isolation element and one is a containment element, arranged at a radially outer position with respect to the corresponding transmissive element.
For the purposes of the present description and of the subsequent claims, the term “electrical energy transmissive element” is used to indicate any element capable of transmitting electrical energy such as, for example, a metallic conductor element. As an illustrative example, if we consider a cable for transporting or distributing medium/high voltage electrical energy (where medium voltage indicates a voltage comprised between about 1 kV and about 30 kV, whereas high voltage indicates a voltage greater than about 30 kV), the “core” of the cable further comprises an inner semiconductive coating layer arranged at a radially outer position with respect to the conductor element, an outer semiconductive coating layer arranged at a radially outer position with respect to the electrical isolation element, a metallic screen arranged at a radially outer position with respect to said outer semiconductive coating layer, and an external layer arranged at a radially outer position with respect to said metallic screen.
For the purposes of the present description and of the subsequent claims, the term “optical signal transmissive element” is used to indicate any transmission element comprising at least one optical fibre. Therefore, such a term identifies both a single optical fibre and a plurality of optical fibres, optionally grouped together to form a bundle of optical fibres or arranged parallel to each other and coated with a common coating to form a ribbon of optical fibres. As an illustrative example, if we consider an optical cable the “core” of the cable further comprises a coating layer arranged at a radially outer position with respect of the grooved core, a tensile reinforcing layer at a radially outer position with respect to said outer coating layer, and an external layer arranged at a radially outer position with respect to said tensile reinforcing layer.
For the purposes of the present description and of the subsequent claims, the term “mixed electro-optical transmissive element” is used to indicate any element capable of transmitting both electrical energy and optical signals in accordance with the abovementioned definitions.
For the purposes of the present description and of the subsequent claims, the term “coating layer” means any coating deposited on the transmissive element of a cable for protective purposes, e.g. to preventing the damages of the transmission element due to mechanical stresses during manufacturing, installation and use.
The present inventions also refers to cables provided with a plurality of cores as defined above, known in the field with the terms “bipolar cable”, “tripolar cable” and “multipolar cable”, depending on the number of cores incorporated therein (in the mentioned cases in number of two, three, or greater, respectively).
In accordance with the abovementioned definitions, the present invention refers to cables provided with one or more cores of any type. In other words, the present invention refers to unipolar or multipolar cables, of electrical type for transporting or distributing electrical energy, or of the optical type comprising at least one optical fibre, or of the mixed energy/telecommunications type.
2. Description of the Related Art
Nowaday, the possibility of using polymer obtained from waste materials for the manufacturing of new products, is a problem of increasing importance for ecological reason and for reducing costs.
In the field of cables, some efforts have been already done in order to use recycled polymer materials, in particular polyvinyl chloride or ethylene polymers obtained from waste cable sheaths. Said recycled polymer materials are generally used for making cable coating layers.
For example, JP 2002/080671 discloses a polyvinyl chloride-based recycled plastic composition obtained by mixing and melting covering plastics and sheaths of waste cables containing: (A) polyvinyl chloride and (B) polyethylene or silane-crosslinked polyethylene, with chlorinated polyethylene. The abovementioned polyvinyl chloride-based resin is said to be useful for making cable sheaths.
JP 2001/098124 relates to a thermoplastic resin composition and to an electrical cable covered with said composition. The thermoplastic resin composition comprises: (A) 1-99 parts by weight of a resin composition containing a polyvinyl chloride resin and a polyethylene resin, said polyvinyl chloride resin and polyethylene resin obtained from waste electrical cables; and (B) 1-99 parts by weight of a multiphase graft copolymer containing (i) 5%-99% by weight of thermoplastic elastomeric units and (ii) 1%-95% by weight of vinyl polymer units where one of the units form a dispersed phase with a particle size of between 0.001 μm-10 μm in the other units. The abovementioned resin composition is said to have a good flexibility and processability when used as an insulating layer or sheath for a cable.
JP 2002/363364 relates to a recycled polyvinyl chloride resin composition comprising a plasticizer having a molecular weight of at least 500 such as, for example, a trimellitate-based, a polyester-based or an epoxy-based plasticizer. The abovementioned composition is said to be useful as covering materials for electrical cables.
JP 2002/363363 relates to a recycled polyvinyl chloride-containing resin composition and to an electrical wire or cable made therefrom. Said composition comprises 100 parts by weight of a 99:1 to 70:30 mixture of a polyvinyl chloride resin which typically is a recycled material and a polyolefin resin, and 1-20 parts by weight with respect to 100 parts by weight of said mixture, of a block copolymer of an acrylic polymer and a hydrogenated polybutadiene in a ratio of 50:50 to 10:90. The abovementioned composition is said to be useful as a covering material for wires and cables.
JP 2002/103329 relates to a method for recycling used vinyl films (e.g. polyvinyl chloride films) for agriculture. The method comprises cutting the used vinyl films roughly; removing impurities such as metals and sand from cut pieces; feeding dried fluff obtained by grinding, washing, dehydrating, and drying said pieces, a plasticizer, a heat stabilizer, and other additives to a heater mixer; keading them; feeding the mixture in a semi-molten state to a cooler mixer; stirring it feeding it to an extruder; extruding it under heated conditions; passing trough a water bath; and pelletizing it. The obtained pellets are dried to form a compound for molding the electrical cable sheath material. Said electrical cable is said to have good properties comparable to a cable having a virgin polyvinyl chloride sheath.
However, the use of recycled polymers may show some drawbacks. In particular, the Applicant has noticed that the use of recycled polyethylene may provide coating layers having poor mechanical properties, in particular stress at break and elongation at break, and poor environmental stress cracking resistance, with respect to those obtained from virgin polymer materials. Moreover, said coating layers may show poor appearance, mainly due to the formation of defects on their surface such as, for example, little agglomerates, which impair not only their appearance and smoothness but also their mechanical properties.
The Applicant believes that the above drawbacks may be due to partial degradation of polyethylene upon prolonged exposure to sunlight and to atmospherical agents, and/or to reprocessing to which said polyethylene is subjected, such degradation causing worsening of mechanical properties and processability.
SUMMARY OF THE INVENTION
Applicant has found that a polyethylene obtained from waste material, in particular a polyethylene obtained from used agricultural films, may be advantageously used for the manufacturing of a coating layer of a cable. In particular, the Applicant has found that the addition of at least one polyethylene having a density higher than 0.940 g/cm 3 to said recycled polyethylene, allows to obtain a coating material able to overcome the above mentioned drawbacks. As a matter of fact, said coating material may be advantageously used in the manufacturing of a coating layer of a cable, said coating layer showing mechanical properties (in particular, stress at break and elongation at break) comparable to those obtained from a virgin polyethylene. Moreover, said coating layer shows a good hot pressure resistance. Furthermore, said coating layer shows an improved environmental stress cracking resistance with respect to the coating layer obtained from a recycled polyethylene alone.
In a first aspect, the present invention thus relates to a cable including at least one core comprising at least one transmissive element and at least one coating layer made from a coating material, wherein the coating material comprises:
at least a first polyethylene having a density not higher than 0.940 g/cm 3 , preferably not lower than 0.910 g/cm 3 , more preferably of between 0.915 g/cm 3 and 0.938 g/cm 3 , and a Melt Flow Index (MFI), measured at 190° C. with a load of 2.16 Kg according to ASTM D1238-00 standard, of between 0.05 g/10 min, and 2 g/10 min, preferably of between 0.1 g/10 min and 1 g/10 min, said first polyethylene being obtained from a waste material; at least a second polyethylene having a density higher than 0.940 g/cm 3 , preferably not higher than 0.970 g/cm 3 , more preferably of between 0.942 g/cm 3 , and 0.965 g/cm 3 .
Preferably, said coating layer is a cable external layer having a protective function.
According to a further aspect, the present invention also relates to a process for producing a cable including at least one core comprising at least one transmissive element and at least one coating layer made from a coating material, said process comprising the steps of:
providing at least a first polyethylene having a density not higher than 0.940 g/cm 3 , preferably not lower than 0.910 g/cm, more preferably of between 0.915 g/cm 3 and 0.938 g/cm 3 , and a Melt Flow Index (MFI), measured at 190° C. with a load of 2.16 Kg according to ASTM D1238-00 standard, of between 0.05 g/10 min and 2 g/10 min, preferably of between 0.1 g/10 min and 1 g/10 min, in a subdivided form, said first polyethylene being obtained from a waste material; providing at least a second polyethylene having a density higher than 0.940 g/cm 3 , preferably not higher than 0.970 g/cm 3 , more preferably of between 0.942 g/cm 3 and 0.965 g/cm 3 , in a subdivided form; conveying at least one core comprising at least one transmissive element into an extruding apparatus comprising a housing and at least one screw rotatably mounted into said housing, said housing including at least a feed hopper and at least a discharge opening; feeding said first and second polyethylenes to said extruding apparatus; melting and mixing said first and second polyethylenes in said extruding apparatus to form a homogeneous mixture; filtering said mixture; depositing said mixture onto said core comprising at least one transmissive element so as to obtain the coating layer.
For the purpose of the present description and of the subsequent claims, the expression “in a subdivided form”, generally means a product of granular form, with an average diameter generally of between about 0.5 mm and about 5 mm, preferably of between 1 mm and about 4 mm, more preferably of between 1.5 mm and 3 mm.
Preferably, said extruding apparatus is a single-screw extruder.
Preferably said melting and mixing is carried out at a temperature of between 150° C. and 250° C., more preferably of between 120° C. and 230° C.
According to one preferred embodiment, said first polyethylene and said second polyethylene are premixed before the step of feeding them to the extruding apparatus.
According to one preferred embodiment, said coating material may further comprise a carbon black.
According to a further preferred embodiment, said first polyethylene has a melting point lower than 130° C., preferably of between 100° C. and 125° C.
According to a further preferred embodiment, said first polyethylene has a melting enthalpy (ΔH m ) of between 50 J/g and 150 J/g, preferably of between 80 J/g and 140 J/g.
Said melting enthalpy (ΔH m ) may be determined by Differential Scanning Calorimetry with a scanning rate of 10° C./min: further details regarding the analysis method will be described in the examples given hereinbelow.
Said first polyethylene may further comprise a carbon black. Generally, said carbon black may be present in the polyethylene in an amount higher than 2% by weight, preferably of between 2.5% by weight and 4.0% by weight, with respect to the total weight of the polyethylene.
Said first polyethylene may be selected from low density polyethylene (LDPE), linear low density polyethylene (LLDPE), very low density polyethylene (VLDPE), or mixtures thereof. Mixtures of low density polyethylene with a small amount of linear low density polyethylene, preferably an amount not higher than 15% by weight with respect to the total weight of the polyethylene, are particularly preferred.
According to one preferred embodiment, said first polyethylene is present in the coating material in an amount of between 30% by weight and 90% by weight, preferably of between 40% by weight and 60% by weight, with respect to the total weight of the coating material.
Examples of said first polyethylene which may be used according to the present invention and which are currently commercially available are the products coming from used agricultural polyethylene films (e.g. the products Alfaten® from Alfagran).
According to one preferred embodiment, said second polyethylene has a Melt Flow Index (MFI), measured at 190° C. with a load of 2.16 Kg according to ASTM D1238-00 standard, of between 0.05 g/10 min and 2 g/10 min, preferably of between 0.1 g/10 min and 1 g/10 min.
According to a further preferred embodiment, said second polyethylene has a melting point higher than 120° C., preferably of between 125° C. and 165° C.
According to a further preferred embodiment, said second polyethylene has a melting enthalpy (ΔH m ) of between 125 J/g and 200 J/g, preferably of between 130 J/g and 185 J/g.
Said melting enthalpy (ΔH m ) may be determined by Differential Scanning Calorimetry as disclosed above.
According to a further preferred embodiment, said second polyethylene is a polyethylene obtained from waste material. Optionally, said polyethylene obtained from waste material comprises a small amount, preferably an amount not higher than 15% by weight with respect to the total weight of the polyethylene, of polypropylene.
According to one preferred embodiment, said second polyethylene is present in the coating material in an amount of between 10% by weight and 70% by weight, preferably of between 40% by weight and 60% by weight, with respect to the total weight of the coating material.
Examples of said second polyethylene which may be used according to the present invention and which are currently commercially available are the products DGDK-3364® Natural from Dow Chemical, or the products coming from used polyethylene bottles (e.g. from Breplast).
In order to protect the coating material from UV degradation said coating material, as reported above, may further comprise carbon black. Preferably, the carbon black is added to the coating material in an amount of between 2% by weight and 5% by weight, preferably of between 2.5% by weight and 4.0% by weight, with respect to the total weight of the coating material. The carbon black may be added to the coating material as such or as a masterbatch in polyethylene. Masterbatch is particularly preferred.
Other conventional additives may be added to the coating material according to the present invention such as, for example antioxidants, processing aids, lubricants, pigments, foaming agents, plasticizers, UV stabilizers, flame-retardants, fillers, thermal stabilizers, or mixtures thereof.
Conventional antioxidants suitable for the purpose may be selected from antioxidants of aminic or phenolic type such as, for example: polymerized trimethyl-dihydroquinoline (for example poly-2,2,4-trimethyl-1,2-dihydroquinoline); 4,4′-thiobis-(3-methyl-6-t-butyl)-phenol; pentaerythryl-tetra-[3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate]; 2,2′-thiodiethylene-bis-[3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate], or the mixtures thereof.
Conventional processing aids suitable for the purpose may be selected, for example, from: calcium stearate, zinc stearate, stearic acid, paraffin wax, or mixtures thereof.
Conventional fillers suitable for the purpose may be selected, for example, from glass particles, glass fibers, calcinated clay, talc, or mixtures thereof.
The coating material according to the present invention may be either crosslinked or non-crosslinked according to the required countries specifications. Preferably, said coating material is non-crosslinked.
If crosslinking is carried out, the coating material comprises also a crosslinking system, of the peroxide or silane type, for example. It is preferable to use a silane-based crosslinking system, using peroxides as grafting agents. Examples of organic peroxides that may be advantageously used, both as crosslinking agents or as grafting agents for the silanes, are dicumyl peroxide, t-butylcumylperoxide, 2,5-dimethyl-2,5-di(t-butylperoxy)-hexane, di-t-butylperoxide, t-butylperoxy-3,3,5-trimethyl-hexanoate, ethyl-3,3-di(t-butylperoxy)butyrate. Examples of silanes that may be advantageously used are (C 1 -C 4 )-alkyloxyvinylsilanes such as, for example, vinyldimethoxysilane, vinyltriethoxysilane, vinyldimethoxyethoxysilane.
The crosslinking system may also comprise a cross-linking catalyst selected from those known in the art. In the case of crosslinking with silanes, for example, lead dibutyl dilaurate may be advantageously used.
Said first polyethylene may be obtained from waste material as a product in subdivided form by means of processes known in the art. For example, said product in a subdivided form may be obtained by means of a process comprising the following steps:
(a) sorting out the impurities (such as, for example, metal, paper, etc) optionally present in a waste material (for example, by feeding said waste material to a conveyor belt and manually sorting out the impurities); (b) feeding the waste material obtained in step (a) [(for example, by means of the same conveyor belt used in step (a)], to a mill obtaining flakes having an average diameter generally of between about 0.1 cm and about 2.0 cm; (c) washing the flakes obtained in step (b) in water and filtering the same in order to discard the impurities having a density higher than 1 kg/l; (d) drying the flakes obtained in step (c) (for example, in a drying apparatus) with warm and dry air; (e) feeding the dried flakes obtained in step (d) to an extruding apparatus comprising a housing and at least one screw rotatably mounted into said housing, including at least a feed hopper and a discharge opening; (f) melting and mixing said flakes obtaining a homogeneous mixture; (g) filtering and granulating the homogeneous mixture obtained in step (f) obtaining a product in a subdivided form; (h) cooling the product in a subdivided form obtained in step (g) (for example, in water); (i) drying the cooled product obtained in step (h) (for example, in a drying apparatus) with warm and dry air.
Preferably, the homogeneous mixtures obtained in step (f) is fed to a second extruding apparatus to obtain a more homogeneous mixture.
Preferably, said extruding apparatuses are single-screw extruders.
Preferably, the granulation in step (g) may be carried out, by means of chopping or shredding the homogeneous mixture obtained in step (f) by means of cutting devices known in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
Further details will be illustrated in the following, appended drawings, in which:
FIG. 1 shows, in cross section, an electrical cable of the unipolar type according to one embodiment of the present invention;
FIG. 2 shows, in cross section, an electrical cable of the tripolar type according to a further embodiment of the present invention;
FIG. 3 shows, in perspective view, a length of cable with parts removed in stages, to reveal its structure according to a further embodiment of the present invention;
FIG. 4 , shows, in cross section, an optical cable according to a further embodiment of the present invention;
FIG. 5 , shows, in cross section, an optical cable according to a further embodiment of the present invention;
FIG. 6 shows, in perspective view, a length of an optical cable with parts removed in stages, to reveal its structure according to a further embodiment of the present invention;
FIG. 7 a and FIG. 7 b show respectively a side view and a partial plan view of a process line according to one embodiment of the present invention;
FIG. 8 shows a full scale photograph of an extruded coating layer obtained from recycled polyethylene alone (sample (A)) and an extruded coating layer obtained from the coating material according to the present invention (sample (B)).
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , cable 1 comprises a conductor 2 , an internal insulating coating layer 3 and an external layer 4 which may be made according to the present invention.
Referring to FIG. 2 , cable 1 comprises three conductors 2 , each one covered by an insulating coating layer 3 . The conductors 2 thus insulated are wound around one another and the interstices between the insulated conductors 2 are filled with a filler material that forms a continuous structure having a substantially cylindrical shape. The filler material 5 is preferably a flame-retarding material. An external layer 6 , which may be made according to the present invention, is applied, generally by extrusion, to the structure thus obtained.
Referring to FIG. 3 , cable 11 comprises, in order from the centre outwards: a conductor 12 , an internal semiconducting layer 13 , an insulating coating layer 14 , an external semiconducting layer 15 , a metallic screen 16 , and an external layer 17 .
The conductor 12 generally consists of metal wires, preferably of copper or aluminium, stranded together according to conventional techniques. The internal and external semiconducting layers 13 and 15 are extruded on the conductor 12 , separately or simultaneously with the insulating coating layer 14 . A screen 16 , generally consisting of electrically conducting wires or tapes, wound spirally, is usually arranged around the external semiconducting layer 15 . Said screen is then covered with an external layer 17 , which may be made according to the present invention.
The cable may in addition be provided with an outer protective structure (not shown in FIG. 3 ), which mainly performs the function of mechanical protection of the cable against impact and/or compression. Said protective structure may be, for example, a metallic armour or a layer of expanded polymeric material as described in patent application WO 98/52197.
FIG. 4 is a sectional view of an optical cable 1 a consisting of an external layer 2 a which may be made according to the present invention, a certain number of tubes 3 a of polymeric material within which are housed the optical fibres 4 a , normally embedded in a packing material 5 a which has the purpose of preventing the longitudinal propagation of water in case of accidental rupture; the tubes containing the optical fibres are wound around a central support 6 a normally made of glass-fiber reinforced plastic and capable of limiting the thermal contractions of the cable (the stranding may be of the continuous or alternate type, commonly called S-Z). Optionally, there may be inserted between the external layer 2 a and the tubes 3 a an interstitial packing material 7 a capable of penetrating into the interstices between the tubes and the coating, between one tube and the next, and between the tubes and the support, in order to limit the longitudinal propagation of water inside the cable.
FIG. 5 is a sectional view of an optical cable similar to that described in FIG. 4 , with the difference that inside the external layer 2 a there is a tensile reinforcing layer 8 a (for example a glass fiber or polyaramid fiber such as the product known commercially as Kevlar®); additionally, the tubes 3 a containing the optical fibres are surrounded by a sheath of a polymeric material 2 b having one or more layers, which may be made according to the present invention Additionally, according to the embodiment shown in FIG. 5 , the central support comprises a core 6 a , made for example of glass-fiber reinforced plastic or similar materials, capable of limiting the thermal contractions of the cable, and a coating 6 b , made for example of polymeric material, such that it increases the diameter of the core to a value capable of receiving the desired number of tubes wound around it.
FIG. 6 is a perspective view of an optical cable 11 a according to the present invention in which the optical fibres 13 a are located in housings in a central grooved core 12 a made of polymeric material, which if necessary may be in contact with a suitable packing 14 a ; the grooved core may optionally contain a central support made of glass-fiber reinforced plastic 15 a . The grooved core is therefore surrounded by a set of layers ( 16 a , 16 b ) at least one of which may be made according to the present invention, and by a tensile reinforcing layer 17 a which as been described above; optionally, the cable structure may also comprise a tape for the purposes of containment and/or protection of the fibers 18 a and a wet-expanding tape 18 b (for example a polyester or polyamide tape filled with wet-expanding material, such as sodium polyacrylate) for the purpose of limiting the longitudinal propagation of water inside the cable.
FIGS. 1 , 2 , 3 , 4 , 5 and 6 show just some possible embodiments of a cable according to the present invention.
Referring to FIG. 7 a and FIG. 7 b , the main steps of a processing line for producing cables in accordance with the present invention are shown in schematic form, said process comprising the following steps:
a step of unwinding a core comprising at least one transmissive element from a feeding reel and conveying said core inside of the extrusion head of a given extruder; a step of feeding a first polyethylene and a second polyethylene forming the coating layer of said cable into said extruder; a step of melting and mixing said first and second polyethylenes within the extruder, followed by the steps of filtrating the obtained mixture and conveying the filtrated mixture into the extrusion head where the coating layer thus obtained is deposited around the aforesaid core; a step of cooling the cable thus produced, and a phase of collecting the finished cable on a reel.
In the case where the coating material used is of a crosslinkable type, a crosslinking operation is provided upstream from the cooling stage.
More specifically, FIG. 7 a represents a schematic side view of processing line 20 referred to above, and FIG. 7 b represents a partial plan view of said line 20 , in which the first stages of said process are shown.
With reference to the aforesaid FIG. 7 a and FIG. 7 b , a core 21 comprising a conductor, for example a conductor made of copper, and an insulating coating layer, is unwound from a feeding reel 22 according to any known technique and conveyed towards the extrusion head of an extruder 23 , for example an extruder of the screw type turned by a motor of conventional type (not represented).
In FIG. 7 b , a second feeding reel 22 ′, in non-operating position, which substitutes first reel 22 once the unwinding operation of core 21 from said first reel is completed, is shown.
Also shown in FIG. 7 a is a system 24 consisting of a plurality of pulleys and gears whose purpose is to ensure a regular and continuous feeding of the core 21 to extruder 23 , especially at the stage where reel 22 is exhausted, and also a constant pull on core 21 , at a predefined speed, so as to ensure uniform extrusion of the coating layer onto the core 21 .
In general the forward speed of the core is between 10 m/min to 1000 m/min.
Simultaneously with the unwinding of the core 21 from feeding reel 22 , the first polyethylene, the second polyethylene and the conventional additives optionally present in the coating material referred to above, are fed into the inlet of extruder 23 in a known manner, for example by means of a hopper 25 . The first polyethylene, the second polyethylene and the conventional additives optionally present in the coating material, as reported above, may be premixed before being fed to the extruder, in a device upstream from the processing line represented in FIG. 7 a or FIG. 7 b . The premixing of the first polyethylene with the second polyethylene and with the conventional additives optionally present in the coating material, may be carried out, for example, in a Banbury mixer, in a twin-screw extruder, or during the process for obtaining the first polyethylene in a subdivided form above disclosed.
Preferably, for the aim of the present invention, the first polyethylene, the second polyethylene and the conventional additives optionally present in the coating material, are premixed in the extruding apparatus used in step (e) of the process for obtaining the first polyethylene in a subdivided form above disclosed.
Said first polyethylene, said second polyethylene, and the conventional additives optionally present in the coating material, as such or premixed, are charged inside of hopper 25 by means of suction nozzles which draw the material directly from packing containers.
Within extruder 23 , said polyethylenes with the conventional additives optionally present, are homogeneously mixed and brought to plastification, i.e. to the molten state, by the work performed by the screw which pushes the coating material of the coating layer, imparting to it, moreover, the pressure necessary to overcome the pressure losses due to the presence of the various components which form the extrusion line.
The obtained coating material is then subjected to a filtration step, which will be better described below, and in the final portion of extruder 23 it is deposited on the core 21 so as to obtain the desired coating layer.
In the shown embodiment, this cable is then subsequently subjected to a suitable cooling cycle effected by moving the cable inside of a cooling channel 26 containing a suitable fluid, generally water at environmental temperature.
Furthermore, in FIG. 7 a is shown a system 27 for multiple passage of the cable in cooling channel 26 , this system consisting, for example, of a storage unit for the processing line capable of guaranteeing an accumulation of cable on a scale sufficient to ensure a forward speed of the cable that is constant and equal to the preset value.
This system 27 can also fulfil the function of making the cable thus obtained to follow a longer path within cooling channel in order to guarantee a more efficient cooling cycle of the cable itself.
Finally, downstream from this cooling stage, the cable is dried by means of air blowers (not represented) and then wound onto a collector reel 28 and sent to a storage area.
The filtration operation of the coating material, plasticized and rendered homogeneous by said screw, is performed by means of the positioning of a filter pack downstream from said screw, at the inlet to a connecting duct which links the extrusion head with the housing within which the extrusion screw is moved.
The filter pack may comprises one or more filter screens placed in series, generally three or even more filter screens, which are supported on a filter support plate 32 .
It should be emphasized that the choice of the number and the type of the filter screens to be used in the filtration section of a production process is markedly influenced by the chemical and physical properties of the coating material to be subjected to filtration.
The process for producing a cable disclosed in FIG. 7 a and in FIG. 7 b , is described with reference to the case in which it is required to make a single core (unipolar) energy cable illustrated in FIG. 1 above disclosed. If different energy cable, or optical cable, or mixed electro-optical cable, are to be produced, the process above described, may be suitably modify as well known in the art.
The present invention is further described in the following examples, which are merely for illustration and must not be regarded in any way as limiting the invention.
Examples 1-5
Preparation of the Coating Materials
Table 1 shows the characterization of the components used in the examples.
The components were the following:
recycled PE: mixture of 90% by weight of low density polyethylene and 10% by weight of linear low density polyethylene, comprising 2.5% by weight of carbon black, coming from used agricultural films; DGDK-3364® Natural: high density polyethylene from Dow Chemical; recycled HDPE: high density polyethylene comprising 10% by weight of isotactic polypropylene coming from used bottles (Breplast); DFDG 6059® Black: linear low density cable jacketing compound from Dow Chemical.
The Melt Flow Index (MFI) was measured at 190° C. with a load of 2.16 Kg according to ASTM D1238-00 standard.
The density was measured, at 23° C., according to CEI EN 60811-1-3 standard.
The melting point and the melting enthalpy (ΔH m ) were measured by Mettler DSC instrumentation (second melting value) with a scanning rate of 10° C./min (instrument head type DCS 30; microprocessor type PC 11, Mettler software Graphware TA72AT.1).
The carbon black content was determined by Mettler TGA instrumentation using the following method:
heating from 20° C. to 85° C. at a scanning rate of 20° C./min in N 2 (60 ml/min); leaving at 850° C. for 1 min in N 2 (60 ml/min); leaving at 850° C. for 10 min in air (60 ml/min).
The obtained data are given in Table 1.
TABLE 1
Melting
Melting
Carbon
Density
point
enthalpy
black
COMPONENT
MFI
(g/cm 3 )
(° C.)
(J/gr)
(%)
Recycled PE
0.45
0.920
121
110
2.5
DGDK-3364 ®
0.70
0.945
127
180
—
Natural
Recycled
0.21
0.960
131
156
—
HDPE
DFDG 6059 ®
0.60
0.932
—
—
2.6
Black
The coating materials given in Table 2 (the amounts of the various components are expressed in % by weight with respect to the total weight of the coating material) were prepared as follows.
Agricultural films were fed to a conveyor belt and the impurities present (metal, paper, etc) were manually sorted out. Subsequently, the films were fed, by means of the same conveyor belt, to a mill obtaining flakes having an average diameter generally of between about 0.1 cm and about 2.0 cm.
The obtained flakes were washed in water and subsequently filtered in order to discard the impurities having a density higher than 1 kg/l. The flakes were subsequently dried in a drying apparatus with warm and dry air.
The dried flakes so obtained, Vibatan® PE black 99415, Anox® HB, DGDK® 3364, recycled HDPE, in the amount given in Table 2, were fed to a first single-screw extruder in 32 D configuration, with rotary speed of about 60 rev/min, with temperature in the various zones of the extruder of 215-225-225-220-225-225° C., the temperature of the extrusion head was 220° C. The obtained mixture was filtered (filter mesh: 180 μm) and subsequently fed to a second single-screw extruder in 32 D configuration, with rotary speed of about 100 rev/min, with temperature in the various zones of the extruder of 128-167-167-177-190-206° C., the temperature of the extrusion head was 200° C. The obtained mixture was filtered (filter mesh: 110 μm) and subsequently granulated with a cutting device having a rotatory blades obtaining granules having an average diameter of about 4 mm.
The obtained granules were then cooled in water and dried in a drying apparatus with warm and dry air.
TABLE 2
EXAMPLE
1 (*)
2
3
4
5 (*)
Recycled PE
100
56
56
51
—
Vibatan ® PE Black
—
3
3
3
—
99415
Anox ® HB
—
1
1
1
—
DGDK-3364 ®
—
—
40
—
—
Natural
Recycled HDPE
—
40
—
45
—
DFDG-6059 ® Black
—
—
—
—
100
(*): comparative.
Vibatan ® PE Black 99415: 40% dispersion of carbon black in low density polyethylene (VIBA Group);
Anox ® HB: 2,2,4-trimethyl-1,2-dihydroquinoline polymer (Great Lakes Chemical).
The obtained granules were subjected to the following analysis.
Hot Pressure Resistance
The hot pressure resistance test at 115° C. was determined according to IEC 60811-3-1 standard.
For this purpose, plates with thickness of 1 mm were prepared by compression moulding at 190° C. and 20 bar after preheating for 10 min at the same temperature.
The obtained plates were subjected to a temperature of 115° C., under a weight of 475 g, for 6 hours. After, their residual thickness was measured. The resistance to hot pressure test is the residual thickness expressed as a percentage of the initial thickness. The obtained data are given in Table 3.
Hardness
The Shore D hardness was determined according to ASTM D2240-03 standard.
For this purpose, plates with thickness of 8 mm were prepared according to the process above disclosed. The obtained data are given in Table 3.
Environmental Stress Crack Resistance (ESCR)
The ESCR was determined according to D-1693 standard, Cond. A.
For this purpose, plates with thickness of 3 mm and cut thickness of 0.65 mm in the case of the coating material of Example 1 (comparative), and with thickness of 2 mm and cut thickness of 0.4 mm in the case of the coating materials of Examples 2-4 according to the present invention and of Example 5 (comparative), were prepared according to the process above disclosed. The measurement was carried out at a temperature of 50° C. in the presence of 10% Igepal solution. The obtained data are given in Table 3.
TABLE 3
EXAMPLE
1 (*)
2
3
4
5 (*)
Hot pressure
30
97.5
96
97
90
resistance
(%)
ESCR
<24
96
96
72
>500
(hours)
Shore D
50
55
55
57
56
(*): comparative.
The data above reported show that the coating materials according to the present invention (Examples 2-4) have hot pressure resistance and Shore D hardness values higher with respect to those obtained from recycled polyethylene alone (Example 1) and comparable or even higher with respect to those obtained from a commercial product (Example 5). With regard to the stress cracking resistance, the coating material according to the present invention shows improved values with respect to those obtained from recycled polyethylene alone.
Examples 6-10
Small cables were then prepared by extruding the coating materials according to Examples 1-5 onto a single red copper wire with a cross-section of 1.5 mm 2 , so as to obtain a 3.4 mm thick cable. The extrusion was carried out by means of a 45 mm Bandera single-screw extruder in 25 D configuration, with rotary speed of about 45 rev/min. The speed line was about 10 m/min, with temperature in the various zones of the extruder of 115-160-190-190-180° C., the temperature of the extrusion head was 180° C.
Samples were taken with hand punches from the extruded layer to measure its mechanical properties in accordance with CEI 20-34, section 5.1, with an Instron instrument at a draw speed of 25 mm/min. The obtained data are given in Table 4.
TABLE 4
EXAMPLE
6 (*)
7
8
9
10 (*)
Stress at
15.8
19.4
18.9
19.8
20.9
break (MPa)
Elongation at
515
622
629
650
710
break (%)
(*): comparative.
The data above reported show that the coating materials according to the present invention (Examples 7-9) have mechanical properties higher with respect to those obtained from recycled polyethylene alone (Example 6) and comparable to those obtained from a commercial product (Example 10).
Furthermore, two samples obtained as reported above were also examined in order to determine the presence of defects on the surface of the extruded coating layers: the enclosed photo (FIG. 8 —full scale) shows that the extruded coating layer obtained from recycled polyethylene alone [Example 6—sample (A)] showed the presence of defects on its surface (e.g. small agglomerates are present); on the contrary, the extruded coating layers obtained from the coating material according to the present invention [Examples 9—sample (B)] did not show any detectable defects on its surface. | A cable including at least one core having at least one transmissive element and at least one coating layer made from a coating material, wherein the coating material has at least a first polyethylene having a density not higher than 0.940 g/cm 3 , preferably not lower than 0.910 g/cm 3 , more preferably 0.915 g/cm 3 to 0.938 g/cm 3 , and a Melt Flow Index (MFI), measured at 190° C. with a load of 2.16 Kg according to ASTM D1238-00 standard, of 0.05 g/10′ to 2 g/10′, preferably 0.1 g/10′ to 1 g/10′; the first polyethylene being obtained from a waste material; at least a second polyethylene having a density higher than 0.940 g/cm 3 , preferably not higher than 0.970 g/cm 3 , more preferably 0.942 g/cm 3 to 0.965 g/cm 3 . Preferably, the coating layer is a cable external layer having a protective function. | 48,956 |
This application is the national phase of International Application No. PCT/CN2011/083179, titled “MAINTENANCE TOOL FOR INSULATOR OF DIRECT CURRENT TRANSMISSION LINE”, filed on Nov. 29,2011, which claims priority to Chinese patent application No. 201020685182.8 titled “MAINTENANCE TOOL FOR INSULATOR OF DIRECT CURRENT TRANSMISSION LINE” and filed with State Intellectual Property Office of PRC on Dec. 28, 2010, the entirety of which are incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The present application relates to the field of the electric power, and particularly to a maintenance tool for an insulator on a direct current transmission line.
BACKGROUND OF THE INVENTION
As the power grid construction of China is improved increasingly, the extra high voltage transmission line becomes the backbone of the power grid frame of China, which also has a higher requirement on the maintenance work. Especially as the 660 kV grade of direct current transmission line is firstly applied in China, in order to ensure the normal operation of the transmission line and that troubles found during the operation of the transmission line can be solved timely, to thereby ensure the safe operation of the direct current transmission line, it is necessary to develop a set of tools for the maintenance of the transmission line in operation.
One of the primary contents of the maintenance work of the transmission line is to repair and replace an insulator. Most high voltage transmission lines are supported on a crossarm via an insulator which plays a fundamental role of supporting the wire and preventing the current from returning to the ground in the aerial transmission lines. The 660 kV grade of direct current transmission line, compared with the extra high voltage and ultrahigh voltage transmission lines in operation currently, employs a different material, for example, the wire is the aluminum conductor steel reinforced of 4×JL/G3A-1000/45 mm 2 , and the distance between the electrodes of the wire is 18 m. The linear insulator is a V-type composite insulator which has a length of 8.5 m in the light polluted area and 9.2 m in the heavy polluted area. And the tension insulator string is a 550 kN double porcelain insulators in parallel. Influenced by the length of the string of the insulators and the electric clearance, the tower head for carrying the insulators and the transmission lines has a large size, and affected by the project, the vertical load of the lines increases accordingly, which causes the change of the tension, the length and the like, thereby has a higher requirement on the replacement of the insulator in aspects such as the tension and the length. At present, maintenance tools for the transmission line at a voltage grade below 500 kV have been more perfect, however, due to the increase of the voltage grade, the diameter of the transmission line and the length of the insulator string are increased. Thus the maintenance tools have been far from the requirements for the replacement.
SUMMARY OF THE INVENTION
It is provided according to one technical problem to be solved by the present application a maintenance tool for an insulator on a direct current transmission line.
In view of this, the present application adopts the following technical solutions.
A maintenance tool for an insulator on a direct current transmission line including a clamping device configured to be clamped at two ends of the insulator and a tension device configured to be connected between the clamping device. The clamping device includes: a closed clamp configured to be clamped on the insulator, a single string clamp fixed on a towing plate, and a wire end clamp fixed on a wire end yoke plate. The tension device is a mechanical transmission screw rod. When replacing a first insulator at a crossarm end, a cooperation of the single string clamp, the closed clamp and the tension device is used. When replacing a first insulator at a wire end, a cooperation of the wire end clamp, the closed clamp and the tension device is used. When replacing a single insulator or multiple insulators in the middle portion, or a long rod insulator, two closed clamps and two tension devices are sufficient for the replacing of the insulator.
The structure of the closed clamp is that: the closed clamp includes a closed clamp main body and an upper cover arranged on the closed clamp main body. One end of the upper cover is moveably connected to the closed clamp main body via a pin shaft, and the other end of the upper cover is fixedly connected to the closed clamp main body via a bolt. A through hole for receiving the insulator is formed between the closed clamp main body and the upper cover. Each of two end portions of the main body is provided with a pin hole for connecting the tension device; and an inner side of the pin hole is provided with a lifting device for lifting the insulator.
The improvements of the closed clamp lie in that: the lifting device is a support fixed on the closed clamp main body, and the support is provided with a pulley wheel for hanging a cable; the lifting device is configured for lifting a heavy long rod insulator in replacing the long bar insulator.
The structure of the single string clamp is that: the single string clamp includes a single string clamp main body. A wing plate is arranged on each of two sides of the single string clamp main body, and an end portion of the wing plate is provided with a pin hole for connecting the tension device. A lower portion of the main body is fixedly connected with an insert plate having a clamping groove, and a lower end portion of the insert plate is provided, at a position corresponded to that of a connecting hole on the towing plate, with a pin hole.
The structure of the wire end clamp is that: the wire end clamp includes a wire end clamp main body and a plate turning clamp arranged on the wire end clamp main body. One end of the plate turning clamp is movably connected with the wire end clamp main body via a pin shaft, and the other end of the plate turning clamp is fixedly connected with the wire end clamp main body via a bolt. A through hole for receiving a wire end yoke plate is formed between the wire end clamp main body and the plate turning clamp. Each of the wire end clamp main body and the plate turning clamp is provided with a hole corresponded to a nut on the wire end yoke plate. Each of two end portions of the wire end clamp main body is movably connected with a steel connector for connecting the tension device.
The improvement of the tension device is that: the tension device includes a mechanical transmission screw rod and a hydraulic device connected to one end of the mechanical transmission screw rod via a locating pin or an insulation pulling rod.
With the above technical solutions, the present application has the following technical progresses.
Based on characters of the direct current transmission line such as the tower-shaped structure, the hanging manner of the insulator string and parameters of the earth wire, the present application provides a maintenance tool for live or power outage maintaining of the long rod insulator, a single porcelain insulator or multiple porcelain insulators on a 660 kV direct current transmission line. The maintenance tool has advantages such as a proper structure, a high overall strength, a small volume, a light weight and a reliable operation, thereby providing a reliable guarantee for the safe commissioning as well as the routine maintenance after the commissioning of the 660 kV direct current transmission line.
The arrangement of the lifting device on the closed clamp enables the operator to lift a heavy long rod insulator during the replacing operation of the long rod insulator, which reduces the labor intensity and increases the working efficiency of the operator.
The tension device is configured to be a composition of the mechanical transmission screw rod and the hydraulic device for shortening or enlarging idle strokes of the clamps, which overcomes the disadvantages that the hydraulic transmission system has a slow transmission speed when being used for transmitting a large mechanical load, and reduces the working time of the operator when working high above the ground. Besides, the structure has a function of mutual protection, that is, when one of the transmission mechanisms fails, the normal work of the other transmission mechanism would not be influenced, thereby the operation reliability is greatly improved. Further, since the tension device is assembled from separate structures, when the tension device is in idle, the separate structures may be stored separately, thereby facilitating the replacement and the maintenance.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of a closed clamp;
FIG. 2 is a top view of a closed clamp;
FIG. 3 is a front view of a single string clamp;
FIG. 4 is a schematic structural view of a wire end clamp;
FIG. 5 is a bottom view of FIG. 4 ;
FIG. 6 is a connecting relationship diagram for replacing a long rod insulator according to the present application;
FIG. 7 is a connecting relationship diagram for replacing a first insulator at a wire end according to the present application; and
FIG. 8 is a connecting relationship diagram for replacing a first insulator at a crossarm end according to the present application.
REFERENCE NUMBERS IN THE FIGURES
1 . closed clamp, 11 . closed clamp main body, 12 . upper cover, 13 . support, 14 . pulley wheel, 2 . single string clamp, 21 . single string clamp main body, 22 . wing plate, 23 . clamping groove, 24 . insert plate, 3 . wire end clamp, 31 . wire end clamp main body, 32 . plate turning clamp, 33 . steel connector, 4 . mechanical transmission screw rod, 5 . hydraulic device, and 6 . insulation pulling rod.
DETAILED DESCRIPTION
The present application will be illustrated in detail hereinafter in conjunction with the accompanying drawings and the embodiments.
A maintenance tool for an insulator on a direct current transmission line includes a clamping device configured to be clamped at two sides of the insulator and a tension device connected between the clamping device. The clamping device includes a closed clamp 1 , a single string clamp 2 and a wire end clamp 3 . The clamping device is made of a TC4 titanium alloy material, and has characters including a high strength, a good plasticity, a light weight, a small volume, a high load bearing capacity and facilitates working high above the ground.
The closed clamp is clamped on a steel cover of the insulator, the structure of which is shown in FIG. 1 and FIG. 2 . The closed clamp includes a closed clamp main body 11 and an upper cover 12 arranged on the closed clamp main body. One end of the upper cover is movably connected with the closed clamp main body via a pin shaft, and the other end of the upper cover is fixedly connected with the closed clamp main body via a bolt. A through hole for receiving the insulator is formed between the closed clamp main body and the upper cover. Each of two end portions of the main body is provided with a pin hole for connecting the tension device, and an inner side of the pin hole is provided with a lifting device for lifting the insulator. The lifting device is configured as a support 13 fixed on the closed clamp main body, and a pulley wheel 14 for hanging a cable is provided on the support.
The single string clamp is fixedly connected on a towing plate, the structure of which is shown in FIG. 3 . The single string clamp includes a single string clamp main body 21 , a wing plate 22 and an insert plate 24 . The wing plate 22 is provided at each of two sides of the single string clamp main body 21 , and an end portion of the wing plate is provided with a pin hole for connecting the tension device. The insert plate 24 is fixedly connected at a lower portion of the single string clamp main body 21 , a lower portion of the insert plate 24 is formed with a clamping groove 23 , and a lower end portion of the insert plate is provided, at a position corresponded to that of a connecting hole on the towing plate, with a pin hole.
The wire end clamp is fixed on a wire end yoke plate, as shown in FIG. 4 and FIG. 5 . The wire end clamp includes a wire end clamp main body 31 and a plate turning clamp 32 . The plate turning clamp 32 is arranged on the wire end clamp main body, one end of the plate turning clamp is movably connected with the wire end clamp main body 31 via a pin shaft, and the other end of the plate turning clamp is fixedly connected with the wire end clamp main body via a bolt. A through hole for receiving a wire end yoke plate is formed between the wire end clamp main body and the plate turning clamp. Each of the wire end clamp main body 31 and the plate turning clamp 32 is provided with a hole corresponded to a nut on the wire end yoke plate. Each of two end portions of the wire end clamp main body 31 is movably connected with a steel connector 33 for connecting the tension device.
The tension device is connected between the closed clamp and the wire end clamp or between the closed clamp and the single string clamp, and the tension device is a combination of a mechanical transmission screw rod 4 and a hydraulic device 5 . The mechanical transmission screw rod is connected to the hydraulic device via an insulation pulling rod 6 .
First Embodiment
In a case that the present application is use for replacing a single insulator, multiple insulators in the middle portion or a long rod insulator on a 660 kV direct current transmission line, two closed clamps and two tension devices are sufficient, as shown in FIG. 6 . The upper cover of the closed clamp is opened, and is rotated to one side of the closed clamp main body about a pin shaft. Then the closed clamp is clamped on a steel cover at one of two ends of the insulator, and then the upper cover is covered to its original position. Then the upper cover and the closed clamp main body is fixedly connected via a bolt, thereby the closed clamp is fixedly connected on the insulator. Then the mechanical transmission screw rods and the hydraulic devices of the two tension devices are respectively connected to pin holes at ends of the two closed clamps, and then the insulation pulling rod 6 is connected between the mechanical transmission screw rod and the hydraulic device, so as to tension the insulator in the case that the insulator is long.
After the connecting operation, the screw rod is tightened or the hydraulic device is actuated to thereby tension the closed clamps, such that the insulator is relaxed and no tension is applied thereon, and thus the insulator may be replaced. The lifting device on the closed clamp may be used to lift the insulator in cases that the insulator is heavy, which can save the labor resource and improve the safety of the operation.
Second Embodiment
When replacing a first insulator at a wire end on a 660 kV direct current transmission line, a composition of the wire end clamp, the closed clamp and the tension device is used, as shown in FIG. 7 . The difference between the second embodiment and the first embodiment lie in that: one closed clamp is clamped on the steel cover of the first insulator at the wire end; then the plate turning clamp of the wire end clamp is rotated to one side of the wire end clamp main body about a pin shaft such that the wire end yoke plate is clamped between the wire end clamp main body and the plate turning clamp, then the nut on the wire end yoke plate is inserted into the bolt hole of the wire end clamp; and then the other end of the plate turning clamp is fixedly connected with the wire end clamp main body via a bolt; next the mechanical transmission screw rod and the hydraulic device of the tension device is connected between the closed clamp and the wire end clamp, and the insulation pulling rod is connected between the mechanical transmission screw rod and the hydraulic device, thereby the insulator can be tensioned in a case that the insulator is long.
In cases that the first insulator is near to the wire end yoke plate, the tension device may only includes the mechanical transmission screw rod or the hydraulic device.
Third Embodiment
When replacing a first insulator at a crossarm end on a 660 kV direct current transmission line, a composition of the single string clamp, the closed clamp and the tension device is used, as shown in FIG. 8 . The difference between the third embodiment and the second embodiment lie in that, one closed clamp is mounted on the steel cover of the first insulator at the crossarm end; then the insert plate, having the clamping groove, of the single string clamp is mounted on the towing plate such that the connecting hole on the towing plate is aligned with the pin hole of the single string clamp, then a bolt is passed through the holes such that the single string clamp is fixedly connected with the towing plate. | A maintenance tool for an insulator of a direct current transmission line comprises clamping devices and a tensioning device. The clamping devices are mounted at the two sides of the insulator through clamping, and the tensioning device is connected between the clamping devices. The clamping devices comprise a closed clamp ( 1 ), a single serial clamping device ( 2 ) and a wire end clamping device ( 30 ). The clamping device has advantages such as strong overall strength and bearing capacity, small size, light weight, and reliable working, and can be applied to replacement of various insulators on the direct current transmission line, reliably ensuring safe commissioning and regular maintenance of transmission lines. | 17,434 |
APPLICATION CROSS REFERENCE
This application claims the priority benefit of Provisional Application Ser. No. 60/319,189 filed Apr. 16, 2002 the teachings of which are hereby incorporated by reference.
BACKGROUND OF INVENTION
The invention relates to a peptide compound having an improved binding affinity to somatostatin receptors, comprising a somatostatin analogue as the peptide and a chelating group covalently linked to the N-terminal free amino group of said peptide
Such peptide compounds and their radiolabelled derivatives can be used for therapy of somatostatin—receptor positive tumors. Detectably labeled somatostatin—peptide compounds are also useful for in vivo imaging. See in this respect the patent publications of Albert et al. (U.S. Pat. No. 5,753,627; U.S. Pat. No. 5,776,894), of Krenning et al. (U.S. Pat. No. 6,123,916), of De Jong et al. (WO 00/18440), and of Srinivasan et al. (U.S. Pat. Nos. 5,804,157; 5,830,431). Albert et al., disclose complexed somatostatin peptides for in vivo imaging of somatostatin receptor—positive tumors, which peptides are derived from somatostatin analogues, carrying an optionally substituted phenylalanine residue or a beta- or 2-naphthylalanine residue in its 3-position. Selective internal tumor therapy with radiolabelled peptides has become very important in nuclear medicine in the past years. Especially somatostatin derivatives have been successfully applied in the clinic for tumor diagnosis and therapy, showing that the principle of receptor targeting is working in practice. For more than four years already much experience has been gained in clinical trials with the use of 90 Y—labeled DOTA-[Tyr 3 ]-octreotide (DOTA-TOC) for tumor therapy (M. de Jong: Eur. J. Nucl. Med. 26, 1999, 693–698). Yet DOTA-TOC only shows high affinity to the somatostatin receptor subtype 2 (sst 2), whereas the affinity to other somatostatin subtypes, in particular sst 3 and sst 5, which are found also in a variety of tumors, is too low to contribute essentially to tumor targeting. For example, most thyroid tumors express these last-mentioned somatostatin receptor subtypes, but have only low levels of sst 2 (E. B. Forssell-Aronsson et al.: J. Nucl. Med. 41, 2000, 636–642).
SUMMARY OF THE INVENTION
It is the objective of the present invention to provide a peptide compound which has a considerable binding affinity to a plurality of somatostatin receptor subtypes, compared with the above known somatostatin peptides. It is an additional advantage if such a peptide compound should have a substantially improved overall affinity to somatostatin receptors. On account of its multispecificity, such a peptide compound, in particular after labeling with a suitable radionuclide, could be therapeutically used for treating a broader variety of tumors. In addition, after labeling with a suitable detectable element, such a peptide compound should have an improved suitability for in vivo detecting and localizing tissues, in particular tumors and metastases thereof, carrying somatostatin receptor types in varying levels.
This objective can be achieved, according to the present invention, by a peptide compound as defined herein, wherein said somatostatin analogue carries an 1-naphthylalanine or a 3-benzothienylalanine residue in its 3-position.
It has been found, that the new peptide compounds of the invention have an unexpectedly high affinity to a plurality of somatostatin receptor subtypes. This favorable binding affinity makes the new peptide compounds promising candidates both for diagnosis, after labeling, and for tumor therapy. Internalization experiments show a substantially increased internalization rate. Biodistribution experiments in vivo show that the labeled new peptide compounds of the invention have a significantly higher tumor uptake than known somatostatin peptide derivatives.
More in particular, the present invention relates to a new peptide compound as defined above, wherein the peptide is a somatostatin analogue of the general formula
H-(A 0 ) n -A 1 -cyclo[Cys 2 -A 3 -A 4 -A 5 -A 6 -Cys 7 ]-A 8 (I)
wherein:
n is 0 or 1, A 0 is optionally halogenated Tyr or Phe, A 1 is optionally halogenated Tyr, or optionally halogenated or methylated Phe or Nal, A 3 is 1-Nal or 3-benzothienylalanyl, A 4 is Trp, optionally N-methylated in its side-chain, A 5 is Lys, optionally N-methylated in its side-chain, A 6 is Thr, Val, Ser, Phe or Ile, and A 8 is Thr, Trp or Nal, wherein the terminal carboxy group may be modified to an alcohol or an, optionally C1–C3 alkylated, amide group.
Suitable examples of the above new somatostatin analogues of formula I are:
H-(D)Phe-cyclo[Cys-1-Nal-(D)Trp-Lys-Thr-Cys]-Thr-ol (1)
H-(D)Nal-cyclo[Cys-1-Nal-(D)Trp-Lys-Val-Cys]-Thr-NH 2 (2)
H-(D)Phe-cyclo[Cys-(L) 3 -benzothienylalanyl-(D)Trp-Lys-Thr-Cys]-Thr-ol (3)
The above examples are covered by the general formula II, encompassing preferred somatostatin analogues:
H-(Á 0 ) n -(D)Á 1 -cyclo[Cys 2 -(L)A 3 -(D)Trp 4 -Lys 5 -Á 6 -Cys 7 ]-Á 8 (II)
wherein:
n is 0 or 1, Á 0 is optionally halogenated Tyr, Á 1 is optionally halogenated Tyr, or Phe, or Nal, A 3 is 1-Nal or 3-benzothienylalanyl, Á 6 is Thr or Val, and Á 8 is Thr-ol, Thr-OH or Thr-NH 2 .
The inventors have already disclosed results of the above labeled compound (1) of their invention at two Symposia, viz. at Jun. 11–15, 2001, and at Aug. 26–29, 2001. These presentations have been published as Symposium Abstracts in J. Labeled Cpd. Radiopharm. 44, Suppl. 1 (2001), 5697–5699, and in Eur. J. Nucl. Med. 28/8, OS 24 (2001), 966, respectively.
The peptide compound according to the invention comprises a chelating group covalently linked to the N-terminal free amino group of the peptide. Various well-known chelating groups can be used, for example, those selected from:
(i) N 2 S 2 -, N 3 S- and N 4 -tetradentate ring structure containing groups, (ii) isocyanate, carbonyl, formyl, diazonium, isothiocyanate and alkoxycarbimidoyl containing groups, (iii) groups derived from N-containing di- and polyacetic acids and their derivatives, and from (iv) 2-iminothiolane and 2-iminothiacyclohexane containing groups. The chelating groups sub (iii) above are preferred, encompassing chelating groups derived from ethylenediamine tetraacetic acid (EDTA), diethylenetriamine pentaacetic acid (DTPA), ethyleneglycol-OO′-bis(2-aminoethyl)-N,N,N′,N′-tetraacetic acid (EGTA), N,N′-bis(hydroxybenzyl)ethylenediamine-N,N′-diacetic acid (HBED), triethylenetetramine hexaacetic acid (TTHA), substituted EDTA or DTPA, 1,4,7,10-tetraazacyclododecane-N,N′, N″,N′″-tetraacetic acid (DOTA), 1,4,7-triazacyclonane-1,4,7-triacetic acid (NOTA) or 1,4,8,11-tetraazacyclotetradecane-N,N′,N″,N′″-tetraacetic acid (TETA).
The method of linking the chelating group to the somatostatin analogue for obtaining the peptide compound of the invention is generally known in the art. The synthesis of the peptide compound having the above chelating group sub (iv) is described in WO 89/07456.
Generally, for the purpose in view, the peptide compound of the invention is labeled with a detectable element selected from gamma- or positron-emitting radionuclides, Auger-electron-emitting isotopes and paramagnetic ions of nonradioactive elements, or with a therapeutic radionuclide. Suitable detectable elements for imaging purposes are gamma- or positron-emitting radionuclides, selected from the group consisting of 99m Tc, 203 Pb, 66 Ga, 67 Ga, 68 Ga, 72 As, 111 In, 113m In, 97 Ru, 62 Cu, 64 Cu, 52 Fe, 51 Cr, 24 Na, 157 Gd, 52m Mn, 162 Dy, 123 I, 131 I, 75 Br and 76 Br, or paramagnetic ions of elements, selected from the group consisting of nonradioactive Gd, Fe, Mn and Cr. In addition to the use of radioisotopes as detectable elements, which enables in vivo detection by a gamma camera, paramagnetic ions of nonradioactive elements, such as Gd, Fe, Mn or Cr, preferably of Gd, can be used, viz. for in vivo detection by MRI.
For therapeutic purposes the compounds of the invention can advantageously be labeled with therapeutic radionuclides, selected from the group consisting of 186 Re, 188 Re, 77 As, 90 Y, 67 Cu, 169 Er, 121 Sn, 127 Te, 142 Pr, 143 Pr, 198 Au, 109 Pd, 165 Dy, 177 Lu, 161 Tb, 211 At, 123m Rh, 111 In and 153 Sm.
Chelation of the above metal isotopes can easily be effected in a manner known per se for related compounds, for example, by bringing the peptide compound of the invention in contact with a compound, often a salt, of the desired isotope in a suitable solvent or diluent, if desired at higher temperature. The preparation of radioactive-halogen labeled peptide compounds according to the present invention can be carried out by a method as described for related compounds in the above-mentioned WO 00/18440, in order to introduce the desired halogen radionuclide into an aromatic nucleus in position 0 or 1 of the peptide. This labeling can conveniently be performed by introducing a halogen atom or a radioactive halogen atom into an radioactive nucleus, preferably an activated aromatic nucleus such as tyrosyl, present in the above position in the peptide compound, if necessary followed by exchange with the desired halogen radionuclide. The radiohalogenation reaction is preferably performed by reacting the peptide compound with a solution of an alkali metal radionuclide selected from 123 I − , 131 I − , 211 At − , 75 Br − and 76 Br − under the influence of a halide-oxidizing agent, such as chloramine T or iodogen. Alternatively, the above substitution reaction can be carried out with nonradioactive halogen, after which halo-exchange with radioactive halogen is performed, e.g. as described in European patent 165630.
The present invention further relates to a pharmaceutical composition, comprising in addition to a pharmaceutically acceptable carrier and, if desired, at least one pharmaceutically acceptable adjuvant, as the active substance a labeled peptide compound as defined above, or a pharmaceutically acceptable salt thereof. Such pharmaceutical compositions can be used for diagnostic purposes; then the peptide compounds are provided with detectable elements as described above. If the compositions are intended for tumor therapy, advantageously the above-mentioned therapeutic radionuclides can be used for labeling the peptide compounds.
The present invention also relates to a method for detecting and localizing tissues having somatostatin receptors in the body of a warm-blooded living being, This diagnostic method comprises (i) administering to said being a pharmaceutical composition, labeled with a suitable detectable element, as defined above, comprising the active substance in a quantity sufficient for external imaging, and thereupon (ii) subjecting said being to external imaging to determine the targeted sites in the body of said being in relation to the background activity, in order to allow detection and localization of said tissues in said body. The present invention further relates to a method for the therapeutic treatment of tumors, having on their surface somatostatin receptors, in the body of a warm-blooded living being, which comprises administering to said being a pharmaceutical composition labeled with a suitable therapeutic radionuclide, as defined above, comprising the active substance in a quantity effective for combating or controlling tumors.
It is sometimes hardly possible to put the ready-for use radiolabelled composition at the disposal of the user, in connection with the often poor shelf life of the radiolabelled peptide compound and/or the short half-life of the radionuclide used. In such cases the user can carry out the labeling reaction with the radionuclide in the clinical hospital or laboratory. For this purpose the various reaction ingredients are then offered to the user in the form of a so-called “kit”. It will be obvious that the manipulations necessary to perform the desired reaction should be as simple as possible to enable the user to prepare from the kit the radioactive-labeled composition by using the facilities that are at his disposal. Therefore the invention also relates to a kit for preparing a radiopharmaceutical composition. Such a kit according to the present invention may conveniently comprise a peptide compound as defined hereinbefore, viz. derived from a somatostatin analogue carrying an 1-naphthylalanine or 3-benzothienylalanine residue in its 3-position, to which substance, if desired, an inert pharmaceutically acceptable carrier and/or formulating agents and/or adjuvants are added, (ii) a solution of a radionuclide compound selected from the group consisting of 99m Tc, 203 Pb, 66 Ga, 67 Ga, 68 Ga, 72 As, 211 At, 111 In, 113m In, 97 Ru, 62 Cu, 64 Cu, 52 Fe, 52m Mn, 51 Cr, 24 Na, 157 Gd, 186 Re, 188 Re, 77 As, 90 Y, 67 Cu, 169 Er, 121 Sn, 127 Te, 142 Pr, 143 Pr, 198 Au, 109 Pd, 165 Dy, 177 Lu, 161 Tb, 123m Rh and 153 Sm, and (iii) instructions for use with a prescription for reacting the ingredients present in the kit. The kit according to the invention preferably comprises a peptide compound derived from a somatostatin analogue of the general formula I, wherein the symbols have the meanings given hereinbefore.
BRIEF DESCRIPTION OF DRAWINGS
For a better understanding of the present invention, reference may be made to the accompanying drawing win which:
FIG. 1 illustrates a graphical representation of a rat study showing that tumor and non- tumor tissue uptake is receptor specific (except for kidneys) and specifically discloses observed uptake of 111 In-DOTA-[1-Na 3 ]-TATE peptide in somatostatin receptor expressing tissues being blocked by coinjection of non-radioactive, competitor, somatostatin analogs that have various receptor subtype specificity.
DETAILED DESCRIPTION OF THE INVENTION
The invention will now be described in greater detail with reference to the following specific Examples.
EXAMPLE I
Synthesis of Peptide Compounds
The new peptide compounds or peptide conjugates of the invention are synthesized by Fmoc-solid-phase synthesis on 2-chloro-tritylchloride resin (Int. J. Pept. Protein Res. 35, 1990, 161–214). According to this method Fmoc-protected amino acids are successively coupled, each time followed by cleavage of the protecting Fmoc-group in basic medium. Finally cleavage of the fully protected conjugates from the resin, oxidative cyclization to the cystine-containing cyclic peptide, and introduction of the DOTA-chelator, (e.g. as described by Heppeler et al. in Chem Eur. J. 1999; 5: 1974–1981), leads to the desired peptide compounds comprising the somatostatin analogues (1), (2) and (3), mentioned hereinbefore, as the somatostatin analogues carrying DOTA as the metal-chelating moiety, linked to the N-terminal free amino group of the peptide.
EXAMPLE II
Labeling of Peptide Compounds
The above DOTA carrying peptide compounds (1) and (3) are labeled with 111 In by dissolving each compound in 0.01 M acetic acid, mixing this solution with 111 InCl 3 — solution (1 mCi/100 μl) in 0.05 M aqueous sodium acetate at higher temperature, and finally neutralizing the solution with HEPES buffer. Labeling with 90 Y, obtained from a 90 Sr— 90 Y radionuclide generator, is performed as follows. A solution of each of the above DOTA carrying peptide compounds (1) and (3) in 0.01 M acetic acid is treated with 90 Y (1.0 mCi/50 μl 0.5 M acetate solution). The mixture is left for approx. 1 hr at higher temperature to effect chelation.
EXAMPLE III
In Vitro Binding Experiments
In vitro binding affinities are determined using transfected cell lines with somatostatin human receptor subtypes (hsst) 2, 3 and 5, as described by Reubi et al. in Eur. J. Nucl. Med. 27, 2000, 273–282. The affinity profiles (IC 50 values), determined for these somatostatin receptor subtypes, are presented in Tables I and II below. In these tables the results of labeled peptide compounds according to the invention, viz. 90 Y-labelled DOTA-(D)Phe-cyclo[Cys-(D)1-Nal-(D)Trp-Lys-Thr-Cys]-Thr-ol (Y-DOTA-[1-Nal 3 ]-OC; cpd. 8) and 90 Y-labelled DOTA-(D)Phe-cyclo[Cys-(D)3-benzothienylalanyl-(D)-Trp-Lys-Thr-Cys]-Thr-ol (Y-DOTA-[BzThi 3 ]-OC; cpd. 9), are compared with those of Y-DOTA-[2-Nal 3 ]-OC (cpd. 10) and Y-DOTA-[3-Pya 3 ]-OC (cpd. 11), referenced to the respective data of somatostatin 28 (cpd. 0) (Table II). Compounds 10 and 11 are prepared according to a method corresponding to the synthesis of compounds 8 and 9: see Examples I and II. For purpose of comparison, recently published results (Reubi et al.—see above) of an additional series of IC 50 values are also presented in Table I: OC to Y-DOTA-TOC (cpds. 4–7), also referred to the corresponding data of somatostatin S28 (SS-28; cpd. 0).
TABLE I
Cpd. No.
Compound
hsst 2
hsst 3
hsst 5
0
SS-28
2.7 ± 0.3
(19)
7.7 ± 0.9
(15)
4.0 ± 0.3
(19)
4
OC
2.0 ± 0.7
(5)
187 ± 55
(3)
22 ± 6
(5)
5
Y-DOTA-OC
20 ± 2
(5)
27 ± 8
(5)
57 ± 22
(4)
6
Y-DOTA-LAN
23 ± 5
(4)
290 ± 105
(4)
16 ± 3.4
(4)
7
Y-DOTA-TOC
11 ± 1.7
(6)
389 ± 135
(5)
114 ± 29
(5)
Affinity profiles (IC 50 ) for human sst (hsst) 2, 3 and 5 receptors.
All values are IC 50 ± SEM in nM. The number of experiments is given in parentheses.
OC = Octreotide = H-(D)Phe 1 -cyclo[Cys 2 -Phe 3 -(D)Trp 4 -Lys 5 -Thr 6 -Cys 7 ]-Thr 8 -ol
LAN = Lanreotide = H-(D)2-Nal-cyclo[Cys-Phe-(D)Trp-Lys-Val-Cys]-Thr-NH 2
TOC = H-(D)Phe-cyclo[Cys-Tyr-(D)Trp-Lys-Thr-Cys]-Thr-ol
TABLE II
Cpd. No.
Compound
hsst 2
hsst 3
hsst 5
0
SS-28
2.7 ± 0.3
(8)
3.7 ± 0.3
(8)
2.9 ± 0.4
(8)
8
Y-DOTA-[1-Nal 3 ]-OC
3.3 ± 0.2
(3)
26 ± 1.9
(3)
10 ± 1.6
(3)
9
Y-DOTA-[BzThi 3 ]-OC
3.4
13
4.1
10
Y-DOTA-[2-Nal 3 ]-OC
25 ± 1.0
(2)
133 ± 68
(2)
98 ± 12.5
(2)
11
Y-DOTA-[3-Pya 3 ]-OC
22 ± 9
(4)
205 ± 43
(4)
648 ± 165
(4)
The above results show that the peptide compounds according to the present invention (cpds. 8 and 9) have a highly promising affinity profile with respect to somatostatin receptors. They are binding in the same range or even better to sst 5 as cpd. 6 and have significantly higher affinity than cpd. 5 for this receptor, even taken into account the different values for the SS-28 (cpd. 0) determined in separate laboratories (Table I and II). The affinity of cpd. 8 to sst 3 is in the same order of magnitude as for cpd. 5, but approx. five times better than for cpd. 6; compound 9 is even significantly better. Most surprising, however, is the affinity to the important receptor sst 2. Both compounds 8 and 9 have an approx. three times better binding affinity to sst 2 than even compound 7. From the above tables it will be clear, that compounds 10 and 11 have only moderate to low binding affinities to sst 2, 3 and 5.
EXAMPLE IV
Internalization Experiments
The above favorable binding affinity has been confirmed in internalization experiments. Four 111 In-labelled compounds, viz. 111 In-labelled DOTA-[2-Nal 3 ]-OC, 111 In-labelled DOTA-TOC, 111 In-labelled DOTA-OC and an 111 In-labelled peptide compound of the invention, viz. 111 In-labelled DOTA-[1-Nal 3 ]-OC (DOTA-NOC), were tested in parallel in the same internalization assay. The experiments were carried out using 2.5 pmol 111 In-labelled peptide compound per 1 million AR42J cells. The internalization rate is clearly highest with the labeled peptide compound of the present invention, viz. 111 In-labelled DOTA-NOC: at 4 hours 26.6% injected dose (ID) per 1 million cells, compared with 12.0% ID/mio-cells for labeled DOTA-TOC, 8.0% ID/mio-cells for labeled DOTA-OC and only 0.6% ID/mio-cells for labeled DOTA-[2-Nal 3 ]-OC.
EXAMPLE V
Biodistributions In Vivo
Biodistributions were carried out in tumor bearing Lewis rats. 111 In-labelled DOTA-NOC was used for these experiments and injected in Lewis rats bearing CA 20948 or AR42J tumors (see M. de Jong et al.: Eur. J. Nucl Med. 24, 1997, 368–371). In these biodistribution studies 111 In-labelled DOTA-NOC according to the present invention showed a significant higher tumor uptake and lower kidney uptake than 111 In-labelled DOTA-TOC, in comparison tests.
EXAMPLE VI
Binding Affinity
The following example provides comparative data regarding peptides of the formula: (D)Phe 1 -cyclo[Cys 2 -A 3 -(D)Trp 4 -Lys 5 -Thr 6 -Cys 7 ]-A 8
wherein the amino acid at position A 8 is L-threonine and the amino acid at position A 3 is selected from the group consisting of 3-Iodo-Tyrosine (hereinafter 3-I-Tyr), 3-Benzothienlyalanine (hereinafter 3-BzThi) and 1-Napthylalanine (hereinafter 1-Nal). The latter three have the following structures:
The evaluated peptides have the addition of the metal chelating ligand DOTA at the N-terminus and are chelated with stable or radioactive isotopes of Yttrium or Indium as indicated.
Table III, presents the binding affinity of the new compounds to human somatostatin receptor subtypes as compared to the compound, Y-DOTA-TATE, described by Srinivasan et al. (U.S. Pat. No. 5,830,431). The data shows that both new peptide analogs with the amino acids 1-Nal, or 3-BzThi at the A 3 position have very high binding affinity to three subtype of the human somatostatin receptor, which is not observed with the previously described molecules, demonstrating that these compounds will be useful for imaging and therapy of human tumors that express one or more somatostatin receptor subtype especially those which do not express high levels of subtype 2.
TABLE III
In vitro Binding Affinity of Peptide Analogs to Human
Somatostatin Receptor Subtypes
IC 50 values
Peptide
(nM concentration) 2
No.
Compound 1
hsst2
hsst3
hsst5
1
Y-DOTA-TATE
1.6
>1000
187
2
Y-DOTA-[3-I-Tyr 3 ]-TATE
1.2
170
65
3
In-DOTA-[1-Nal 3 ]-TATE
1.6
13
4.3
4
In-DOTA-[3-BzThi 3 ]-TATE
1.1
7
4
Derivatives of the claimed sequence:
(D)Phe 1 -cyclo[Cys 2 -A 3 -Trp 4 -Lys 5 -Thr 6 -Cys 7 ]-Thr 8
Where peptide No. 1 is the comparison peptide with the natural amino acid, L-Tyrosine, at the A 3 position and peptides No. 2 through 4 are compounds of the invention. Peptides are DOTA-ligand linked at the N-terminal position and the DOTA ligand is complexed with stable isotopes of Y (Yttrium-89) or In (Indium-114), and A 3 is one of the amino acids listed in FIG. 1, and the C-terminal amino acid (A 8 ) is Threonine. IC 50 values were determined as described by Reubi et al. (Eur J Nuc Med 28:836–846, 2001).
EXAMPLE VII
Biodistribution Data
Table IV and Table V present the biodistribution properties of Indium-111 radiolabeled versions of the new compounds in a rat tumor model, and show that the compounds have excellent biodistribution characteristics. Most notable are rapid blood clearance, high tumor uptake, predominately renal excretion, and low uptake in tissues which do not express somatostatin receptors. Somostatin receptors are present at high levels in tumor, pancreas and adrenals.
TABLE IV
Biodistribution of 111 In-DOTA-(1-Nal) 3 -TATE in AR42J Tumor
Bearing Lewis Rats (Percent Injected Dose per Gram Tissue).
Tissue
4 hr ± StdDev
24 hr ± StdDev
48 h ± StdDev
Blood
0.04 ± 0.00
0.00 ± 0.00
0.00 ± 0.00
Tumor
4.01 ± 0.50
1.82 ± 0.26
1.11 ± 0.05
Kidneys
1.51 ± 0.09
0.75 ± 0.12
0.74 ± 0.08
Adrenals
10.76 ± 0.55
5.87 ± 1.40
5.22 ± 0.30
Pancreas
12.31 ± 0.88
2.45 ± 0.31
2.16 ± 0.24
Spleen
0.11 ± 0.01
0.04 ± 0.00
0.04 ± 0.01
Stomach
1.83 ± 0.62
0.92 ± 0.11
0.42 ± 0.33
Bowel
0.25 ± 0.07
0.17 ± 0.00
0.14 ± 0.01
Liver
0.09 ± 0.06
0.04 ± 0.01
0.06 ± 0.03
Lung
0.09 ± 0.01
0.03 ± 0.00
0.02 ± 0.01
Heart
0.02 ± 0.00
0.01 ± 0.00
0.01 ± 0.00
Bone
0.02 ± 0.00
0.01 ± 0.00
0.00 ± 0.00
TABLE V
Biodistribution of 111 In-DOTA-(BzThi) 3 -TATE in AR42J
Tumor Bearing Lewis Rats (Percent Injected Dose per Gram Tissue).
Tissue
4 hr ± StdDev
24 hr ± StdDev
48 h ± StdDev
Blood
0.02 ± 0.00
0.01 ± 0.00
0.01 ± 0.01
Tumor
4.12 ± 0.62
2.05 ± 0.75
1.10 ± 0.18
Kidneys
1.79 ± 0.15
1.83 ± 0.17
0.94 ± 0.30
Adrenals
5.71 ± 0.53
3.34 ± 0.72
2.84 ± 0.63
Pancreas
10.33 ± 0.34
3.30 ± 0.20
2.53 ± 0.57
Spleen
0.05 ± 0.01
0.05 ± 0.00
0.10 ± 0.11
Stomach
0.81 ± 0.23
0.66 ± 0.36
0.47 ± 0.07
Bowel
0.15 ± 0.02
0.13 ± 0.01
0.18 ± 0.02
Liver
0.10 ± 0.01
0.07 ± 0.01
0.10 ± 0.09
Lung
0.06 ± 0.00
0.05 ± 0.00
0.10 ± 0.13
Heart
0.01 ± 0.00
0.01 ± 0.00
0.01 ± 0.00
Bone
0.01 ± 0.01
0.01 ± 0.00
0.01 ± 0.00
EXAMPLE VIII
Tissue Uptake
Tumor and non-tumor tissue uptake is receptor specific (except for kidneys) as shown in the rat study presented in FIG. 1, which demonstrates that the observed uptake of 111 In-DOTA-[1-Nal 3 ]-TATE peptide in somatostatin receptor expressing tissues can be blocked by coinjection of non-radioactive, competitor, somatostatin analogs that have various receptor subtype specificity. As expected the efficacy of the unlabeled derivatives to compete with the uptake the radioactive compounds corresponds to expression level of somostatin receptors and specific subtypes.
Having described the invention in detail, those skilled in the art will appreciate that modifications may be made of the invention without departing from its spirit and scope. Therefore, it is not intended that the scope of the invention be limited to the specific embodiments described. | The invention relates to a peptide compound having an improved binding affinity to somatostatin receptors, comprising a somatostatin analogue as the peptide and a chelating group covalently linked to the N-terminal free amino group of said peptide, wherein said somatostatin analogue carries an 1-naphthylalanine or a 3-benzothienylalanine residue in its 3-position. The invention further relates to said peptide compound labeled with a detectable element or with a therapeutic radionuclide, as well as to a diagnostic method and to a method for the therapeutic treatment of tumors, by using the labeled compounds. | 34,916 |
BACKGROUND OF THE INVENTION
The present invention relates to a technology used in a development environment, in which a plurality of simulators execute a coordinated complicated simulation in the development of an embedded system.
An embedded system is a system composed of a mechanism constituting a control object, hardware for performing a control operation based on a physical quantity received from the mechanism and outputting a control value to the mechanism, and software which operates on the hardware. For example, an embedded system of an automotive vehicle is composed of an engine as a control object, an electronic device such as a microcomputer for controlling the engine, and software which operates on the microcomputer. Since the behavior of the software included in the embedded system strongly depends on the mechanism of the control object and the configuration of the hardware, it is necessary to analyze combined behavior of the mechanism, the hardware and the software.
In recent years, embedded systems have become more complicated to make automotive vehicles, electrical apparatuses and the like more reliable and more functional. Accordingly, to shorten a working period, parts of hardware and software are fragmented and specialized and development is simultaneously carried out at a plurality of sites. As fragmentation progresses, deficiency in performance and defect in specification which are ascertained when the parts are assembled are on the increase in addition to checking of the operation of each part. Thus, a delay in development period caused by a rework at a final stage before product shipment frequently occurs, thereby causing a problem of deteriorating development efficiency.
To solve this problem, it has been started to use a performance evaluation and verification technique by a simulation in which the mechanism, the hardware and the software are collaborated at the time of designing. In a mechanism/hardware/software collaborated simulation, a collaborative simulation at the overall product level is executed by mutually connecting different types of simulators since usable simulators differ depending on the configurations of the mechanism and the hardware to be simulated and simulation models created for specific simulators are already accumulated.
Conventionally, to execute a collaborative simulation in which a plurality of simulators are mutually connected, it is necessary to build an execution environment on a computer of each individual. For this, the following five problems exist. The first problem is that it is difficult to share design files and manage progresses due to the simultaneous development at a plurality of sites. The second problem is that cost for manually adjusting the simulators and connection parameters among the simulators increase since different simulators need to be connected.
The third problem is that cost for introduction and maintenance is high since a plurality of simulators are used. The fourth problem is that computational capability becomes insufficient since a plurality of simulators are operated. The fifth problem is a high risk of information leakage since design files are stored in each individual PC.
As one way of coping with the above problems, it is thought to unify development environments. As a known technology on unification of development environments, a computational environment providing service is disclosed in patent literature 1. In this service, a server on a network is rent to a user and the user obtains a computational environment by remotely controlling the server.
CITATION LIST
Patent literature 1: JP2002-24192A
SUMMARY OF THE INVENTION
The technology of the above patent literature 1 can solve the fourth and fifth ones of the above problems, but cannot solve the other problems and service users need to individually deal with them. Problems the present invention seeks to solve are the first to third ones of the problems descried in the above background art.
As described above, the first problem is that it is difficult to share design files and manage progresses due to the simultaneous development at a plurality of sites. Further, the second problem is that cost for manually adjusting the individual simulators and connection parameters among the simulators increases since different simulators need to be connected. Furthermore, the third problem is that cost for introduction and maintenance of the hardware and the software is high and it is difficult to easily execute a simulation since a plurality of simulators and computational resources are necessary.
The present invention has been developed in view of the above problems and an object is to suppress cost required for introduction and maintenance of a development environment including a plurality of simulators, share design information and facilitate adjustment of parameters of the simulators.
An aspect of the present invention solves the first problem by including a mechanism for selecting and recording a simulator or software usage history of each user with high accuracy in embedded system development and another mechanism for selecting a development process of the user from information collected by the former mechanism and recording it.
Further, the second problem is solved by including a mechanism for automatically optimizing a simulation configuration from the information collected by the former mechanism.
Furthermore, the third problem is solved by enabling a reduction in initial investment for environment and facilities by a service which realizes unification of development environments on a computer including the above mechanisms.
Accordingly, since an aspect of the present invention allows simulators or software to be all managed on a server system, embedded system developers need not purchase them in advance and maintain them. Further, since developed software and simulation results using the software are managed on the server system, it becomes easier to share design files and a risk of leaking information to outsiders can be suppressed to a minimum level.
Further, since the developers can easily execute quick and accurate simulations without requiring detailed know-how due to the cooperation of a plurality of simulators and automated adjustment of simulator parameters, development efficiency of the embedded system is improved.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing a first embodiment of the present invention and functional elements of a computer system,
FIG. 2 is a flow chart showing the first embodiment of the present invention and an example of a process performed in a user terminal,
FIG. 3 is a block diagram showing the first embodiment of the present invention and the detailed configuration of the entire system,
FIG. 4 is a flow chart showing the first embodiment of the present invention and an example of a process in a software development mode,
FIG. 5 is a flow chart showing the first embodiment of the present invention and an example of a process in a simulation mode,
FIG. 6 is a flow chart showing the first embodiment of the present invention and an example of a process in a development progress/tool usage status/system usage fee confirmation mode,
FIG. 7 is a diagram showing the first embodiment of the present invention and an example of a screen image of a simulation task input device,
FIG. 8 is a diagram showing the first embodiment of the present invention and an example of a screen image in the case of reusing the configuration of a task created in the simulation task input device,
FIG. 9 is a diagram showing the first embodiment of the present invention and an example of a screen image when an abstraction level of a task input decreases in the simulation task input device,
FIG. 10 is a diagram showing the first embodiment of the present invention and an example of a screen image presenting a simulation task configuration created by the task input device,
FIG. 11 is a diagram showing the first embodiment of the present invention and a task configuration result,
FIG. 12 is a flow chart showing the first embodiment of the present invention and task creation by a simulation task creating device,
FIG. 13 is a diagram showing the first embodiment of the present invention and a configuration example of a cluster node constituting simulation computational resources,
FIG. 14 is a block diagram showing the first embodiment of the present invention and an example of the simulation computational resources,
FIG. 15A is a flow chart showing the first embodiment of the present invention and an example of a process of calculating a system usage fee,
FIG. 15B is a flow chart showing the first embodiment of the present invention and an example of a process of calculating a license fee,
FIG. 16A is a flow chart showing the first embodiment of the present invention and an example of a process of analyzing a development progress,
FIG. 16B is a flow chart showing the first embodiment of the present invention and an example of a process of analyzing a tool usage status,
FIG. 17 is a diagram showing the first embodiment of the present invention and a table configuration example of a resource usage management database and a resource price database,
FIG. 18 is a diagram showing the first embodiment of the present invention and a table configuration example of an operation history database,
FIG. 19 is a diagram showing the first embodiment of the present invention and a table configuration example of a tool/model database,
FIG. 20 is a diagram showing the first embodiment of the present invention and a table configuration example of the resource price database,
FIG. 21 is a diagram showing the first embodiment of the present invention and an example of an information flow graph of a graph structure that a task given from a user by analyzing a temporal sequence and the flow of operations is a base point, simulation trials and file changes are points and a dependency relationship of information is an edge,
FIG. 22 is a diagram showing the first embodiment of the present invention and an example of a development progress report,
FIG. 23 is a diagram showing the first embodiment of the present invention and an example of a command list,
FIG. 24 is a diagram showing the first embodiment of the present invention and an example of a database for managing a state of the simulation computational resources,
FIG. 25 is a diagram showing the first embodiment of the present invention and an example of a tool usage status report,
FIG. 26A is a diagram showing the first embodiment of the present invention and an example of a simulation configuration table of a simulation configuration history database,
FIG. 26B is a diagram showing the first embodiment of the present invention and an example of a simulation configuration table of the simulation configuration history database,
FIG. 27 is a diagram showing the first embodiment of the present invention and an example of a system usage fee report for a user,
FIG. 28 is a diagram showing the first embodiment of the present invention and an example of a license fee report for a software provider, and
FIG. 29 is a block diagram showing a second embodiment of the present invention and functional elements of a computer system.
DETAILED DESCRIPTION OF THE EMBODIMENTS
First Embodiment
Hereinafter, one embodiment of the present invention is described based on the accompanying drawings. FIG. 1 is a functional block diagram schematically showing one example of the embodiment of the present invention and a computer system (development assisting system for embedded devices) for assisting the development of an embedded system.
In a computer system used to develop an embedded system, a dynamic computational resource distribution system 100 , simulation computational resources 101 , a simulation result visualization system 102 , a system load/user behavior monitoring system 103 , a work computer system 106 , a screen data transmission system 104 using secure communication, a user terminal 107 and a software provider terminal 108 are connected via an internal network.
The above configuration is called the present system below. The user terminal 107 and the software provider terminal 108 can access the present system only via the screen data transmission system 104 using secure communication. Note that each of the systems, computational resources and terminals are constructed by a computer including a processor, a memory and an interface.
Further, the embedded system is a combination of a mechanism as a control object, hardware for driving the mechanism and software for controlling the hardware.
A summary of the present system is that embedded software is created in the work computer system 106 in accordance with an input or command from the user terminal 107 and a simulation of the created embedded software is optimized in the dynamic computational resource distribution system 100 .
The dynamic computational resource distribution system 100 executes an optimized simulation task in the simulation computational resources 101 including a plurality of computers. The simulation computational resources 101 includes simulation software (simulators) for executing a simulation, a computer (cluster node 1400 in FIG. 14 ) for executing a simulation, a plurality of applications for executing a plurality of types of simulations, and a plurality of computers for executing the applications.
When a simulation of the embedded software is executed, the user terminal 107 instructs the dynamic computational resource distribution system 100 to execute the simulation. The dynamic computational resource distribution system 100 secures software resources and hardware resources of the simulation computational resources 101 and executes the simulation based on a request from the user terminal 107 .
The screen data transmission system 104 functions as a gateway for transmitting and receiving data to and from the user terminal 107 or the software provider terminal 108 , authenticates the user terminal 107 (or the software provider terminal 108 ), and transmits and receives data to and from the user terminal 107 (or the software provider terminal 108 ) by highly confidential communication (hereinafter, secure communication) such as encrypted communication.
The present system also includes the simulation result visualization system 102 . The simulation result visualization system 102 includes a computer for providing a simulation result calculated by the simulation computational resources 101 such as in the form of a graph to the user terminal 107 .
The present system also includes the system load/user behavior monitoring system 103 . The system load/user behavior monitoring system 103 includes a computer for collecting hardware and software operational statuses of the simulation computational resources 101 , a computer for collecting a progress status of the embedded system developed in response to an input or a command from the user terminal 107 or the like and generates billing information and statistical information for each user terminal 107 . Note that each of the computer systems is described in detail later.
FIG. 2 is a flow chart of a development work of the embedded system performed in the user terminal 107 in the present system. An operation when a user utilizes the present system according to this embodiment using the user terminal 107 is described with reference to FIGS. 1 and 2 .
First in Step 301 , the user connects the user terminal 107 with the screen data transmission system 104 . The screen data transmission system 104 authenticates whether or not the user terminal 107 possesses access authority to the present system. The software provider terminal 108 is similarly connected to the screen data transmission system 104 , and the screen data transmission system 104 authenticates whether or not the software provider terminal 108 possesses access authority to the present system.
Since the user or the software provider certainly accesses via the screen data transmission system 104 after authentication, the description on the access via the screen data transmission system 104 is omitted below.
Subsequently, in Step 302 , the user selects an operation content using the user terminal 107 . The present system includes three operation content modes, which are a software creation mode 315 for creating the embedded software, a simulation mode 316 for executing a simulation to control the mechanism as the control object by the created embedded software and a development progress/tool usage status/system usage fee confirmation mode 317 for obtaining a usage status of the computational resources of the present system. In the above three modes, contents of services to be provided differ and, in addition, methods for calculating a system usage fee differ.
Further, the screen data transmission system 104 requests selection of any one of the above three modes to the user terminal 107 after authentication of the user terminal 107 is completed. When the user terminal 107 notifies a selection result to the screen data transmission system 104 , the screen data transmission system 104 notifies the start of usage from the user terminal 107 to the computer system corresponding to the selected mode. The computer system (dynamic computational resource distribution system 100 , the work computer system 106 or the system load/user behavior monitoring system 103 ) notified of the start of usage from the screen data transmission system 104 starts providing a service to the user terminal 107 .
First, a work flow when the user selects the software creation mode 315 from the user terminal 107 is described. The user terminal 107 develops software for the embedded system by remotely operating the work computer system 106 in Step 304 and stores a created design file in Step 305 . The user terminal 107 stores the design file in a storage device in the work computer system 106 or the present system.
Next, a work flow when the user selects the simulation mode 316 from the user terminal 107 is described. In the case of selecting the simulation mode, the dynamic computational resource distribution system 100 , the simulation computational resources 101 and the simulation result visualization system 102 executes a simulation instructed by the user terminal 107 in response to a command from the user terminal 107 .
First, in Step 307 , the user inputs a simulation configuration (dependency relationship of a plurality of simulation tasks) using a plurality of commercial simulation software (or simulators) to the dynamic computational resource distribution system 100 from the user terminal 107 .
In next Step 308 , the dynamic computational resource distribution system 100 secures the simulators, the simulation result visualization system 102 , and CPUs, a memory capacity, special computing units (accelerators) and a storage area in the simulation computational resources 101 sufficient to perform a simulation task received from the user terminal 107 . The dynamic computational resource distribution system 100 calculates an arrangement relationship of the simulators on the simulation computational resources 101 and constructs an actual simulation task so that the simulation task configuration is optimally executed based on a coupling relationship of the parts (mechanism to be developed, hardware, software) in the simulation task input from the user terminal 107 .
Note that the simulation task, the simulation configuration and the simulation task configuration are defined as below in the following description.
The simulation task indicates a simulation object in which the elements of the mechanism, the hardware and the software in the embedded system are coupled. A plurality of simulations can be included in a simulation task.
The simulation configuration defines a dependency relationship among the simulations when simulations are included in a simulation task.
The simulation task configuration defines a relationship between the cluster nodes 1400 of the simulation computational resources 101 and simulations to be allocated to the cluster nodes 1400 . The simulation task configuration is, for example, expressed by a command list as shown in FIG. 23 .
A task creation result, for example, in the case of developing a control system for an internal combustion engine as an embedded system is shown in FIG. 11 . If a simulation of an engine control ECU (Electronic Control Unit) is a simulation task, simulation elements (parts) are the engine control ECU, an air flow meter, an injector and an engine. Then, a plurality of simulation software programs (simulators) respectively corresponding to the engine control ECU, the air flow meter, the injector and the engine are executed. The cluster nodes 1400 that execute the respective simulators are allocated by the simulation task configuration.
The dependency relationship (simulation configuration) of the simulators is as described below in the example of FIG. 11 . Data such as an intake air amount of the air flow meter are input to the simulator of the engine control ECU. A fuel injection amount and the like from the engine control ECU are input to the simulator of the injector. A fuel injection period and a fuel injection amount from the injector are input to the simulator of the engine. The rotational speed and the like of the engine are input to the simulator of the air flow meter. Further, an engine output is input to a simulator (Loger001.exe of FIG. 11 ) of the entire system. That is, an input/output relationship of data among simulation software programs is the simulation configuration.
Thereafter, the simulation is executed in Step 309 . Specifically, if the user instructs to execute the simulation task configuration constructed in the dynamic computational resource distribution system 100 from the user terminal 107 , the dynamic computational resource distribution system 100 inputs the simulation task to the simulation computational resources 101 . The cluster node 1400 having the simulation task allocated thereto executes the simulation in the simulation computational resources 101 .
Subsequently, a simulation result is displayed in Step 310 . Specifically, the simulation result visualization system 102 analyzes the simulation task configuration input from the user terminal 107 and estimates a simulation result required by the user. The simulation result visualization system 102 further allocates the simulation result meeting the user's request to a simulation result visualization unit 715 in inside. The simulation result visualization unit 715 is an independent program included in the simulation result visualization system 102 and graphs one or more specific types of data by a specific method. There are a multitude of mounting forms depending on a graphing method and the type of data to be received.
The result of the simulation executed in the simulation computational resources 101 is transmitted to the simulation result visualization system 102 . As described above, the simulation result is processed into a form desired by the user and presented to the user terminal 107 via the screen data transmission system 104 using the secure communication.
Next, an operation of collecting and recording information performed in the background of the present system during the execution of the above software creation mode 315 and simulation mode 316 is described.
Information is collected, recorded and its statistics is taken by the system load/user behavior monitoring system 103 . This enables data collected in the development progress/tool usage status/system usage fee confirmation mode 317 described below to be provided to the user.
The system load/user behavior monitoring system 103 monitors and records a GUI operation and a file operation of the user terminal 107 in the work computer system 106 using the secure communication, the input of a simulation from the user terminal 107 in the dynamic computational resource distribution system 100 and system loads on CPUs, memories, network and storages in the simulation computational resources 101 .
The system load/user behavior monitoring system 103 performs several processes using the obtained recorded GUI operation and file operation of the user terminal 107 , a simulation instructed from the user terminal 107 and a system history data. These processes include calculation of a usage fee for the user terminal 107 , creation of a development progress report of the user terminal 107 or a group to which the user belongs, calculation of a license fee payment amount for the software provider providing the simulators introduced into the simulation computational resources 101 , and creation of a usage status report of the simulators introduced into the simulation computational resources 101 .
A work flow when the above development progress/tool usage status/system usage fee confirmation mode 317 is selected is described with reference to FIG. 2 . The present system performs this work using the system load/user behavior monitoring system 103 .
In Step 313 , the user terminal 107 selects the type of information desired to be browsed out of the development progress report, the software usage status report and the system usage fee report. In Step 314 , the user terminal 107 browses the selected information via the screen data transmission system 104 .
If the user is developing the embedded system or the like on the present system by operating the user terminal 107 , the user receives the usage fee information and the development progress report of the present system calculated by the system load/user behavior monitoring system 103 .
If the user is a software provider and provides software to the present system, the user can receive the software usage status and a report on license revenue from the usage of the software which are calculated by the system load/user behavior monitoring system 103 .
Next, the present system is described in detail. FIG. 3 is a block diagram showing a detailed construction of devices necessary to execute the present system. A connection relationship of the devices in FIG. 3 merely shows an example of an embodiment and a widely or publicly known technology may be used if the functions described above can be obtained.
Confirmation of information for user connection (authentication) described in Step 301 of FIG. 2 is executed by a user connection authority confirming device 702 in the screen data transmission system 104 shown in FIG. 3 . An authentication method using the exchange of files including encrypted individual identification information, an authentication method using a device including individual identification information encrypted at a user side and the like as well as a method using an ID number and a password for identifying a user (user terminal 107 ) can be used as an authentication method provided in the user connection authority confirming device 702 .
Further, a method for providing a login program as an application on a web browser, a method for providing a login program as an independent application which operates on a user's personal computer (user terminal 107 ) and a method for introducing and providing an OS (Operating System), which is configured such that only a login program to the present system operates, to the above device including the individual identification information are thought as a method for providing a login program to the present system. However, in the present invention, a widely or publicly known technology may be used if it meets a requirement that communication confidentiality between the user and the present system is ensured and it is impossible for a person who is not authorized to use the present system to log into the present system.
FIG. 4 shows a process flow of the present system in the software creation mode 315 . Using FIGS. 4 and 3 , the process of the present system in the software creation mode 315 is described in detail. The software mentioned here indicates the software of the embedded system to be developed by the user, simulation models necessary in executing a simulation, and the simulation result visualization system 102 .
In Step 401 , the user terminal 107 selects the software creation mode. In Step 402 , the work computer system 106 allocates a work environment suitable for the user using the user terminal 107 . By this allocation, the user terminal 107 can use a tool/model database 709 and the like of the dynamic computational resource distribution system 100 via the work computer system 106 . The work computer system 106 is composed of work computational resources 722 , a user file storage 707 and a work environment providing device 703 to be described later.
In Step 304 , the user develops the software by remotely operating the above allocated work environment from the user terminal 107 . In Step 305 , a design file and the like created by the user are stored in the user file storage 707 . A change made to the user file storage 707 by the user at this time is registered as a file access history in an operation history database 708 for recording a GUI operation and a file history by a file history recording device 714 in Step 404 .
In Step 403 , the GUI operation of the user in the user terminal 107 in the work environment provided by the work computer system 106 is obtained by a user behavior statistics device 713 to be described later and registered in the operation history database 708 . The registered GUI operation history is used to visualize the development progress and used as statistical information of the software usage status.
When the user of the user terminal 107 finishes the development of the software and selects the termination of the work environment in Step 306 , the user behavior statistics device 713 obtains a difference between login time to the work environment and logout time therefrom as a usage time using the function of the OS of the user terminal 107 . The obtained usage time is registered in a resource usage management database 711 for recording the system loads in the present system and used to calculate the usage fee of the software creation mode 315 in Step 405 .
The user file storage 707 of the work computer system 106 is a file storage area arranged on the network and design files created in the software creation mode 315 and simulation log files in the simulation mode 316 are stored therein.
The user file storage 707 is divided into small areas allocated to each user or each group to which the user belongs. Note that the user file storage 707 is classified according to transfer performance and capacity, and a storage usage unit price used at the time of calculating the system usage fee also differs depending on the class.
A used amount or allocated amount is registered in the resource usage management database 711 in advance for each small area (e.g. block) by the function of a storage system constructing the user file storage 707 and used in calculating the system usage fee for the user.
An administrator of the present system maintains the confidentiality of the present system by setting access authorities of the users to read from, write in and refer to an arbitrary small area in advance.
The work computational resources 722 are configured to include a computer in which one or more OSs (Operating Systems) operate. The work computational resources 722 are in a state where the software provided to the present system is usable. For the types of the OSs used to construct the work environment, a widely or publicly known technology may be used. Typically, a plurality of types of OSs are used to enable the operation of all the software provided to the present system.
Further, since the simulator or software used by the user terminal 107 differs, the setting of the OSs provided to the user terminal 107 is typically widely ranging.
With a normal configuration to provide one OS for one computer, the number of computers required to meet the above request increases. However, by using visualization software enabling a plurality of OSs to operate on one computer such as VMWare, the number of computers necessary for the work computational resources provided by the work computer system 106 can be reduced.
Further, the work computational resources 722 requires a function of obtaining the login time of the user terminal 107 , the logout time of the user, the number of usage, usage time and used functions for each type of software used by the user. To realize a function of obtaining these pieces of information, a case where the functions provided by the OSs are used and a case where introduction of software complementing functions not provided by the OSs is necessary are thought. A widely or publicly known technology may be used to realize the functions.
The work environment providing device 703 is a computer which selects an optimal OS configuration from the work computational resources 722 based on the type of the OS meeting the request of the user operating the user terminal 107 and the type of the software used, couples it with the corresponding user area in the user file storage 707 and provides the resultant to the user.
Two methods can be adopted as a method for realizing the coupling of the work computational resources 722 and the user file storage 707 . According to one method, after one or more dedicated work environments are allocated to all the users from the work computational resources 722 , changes made to the work environments by the users during the works other than products stored in the user file storage 707 are also stored in the work environments so as to be reusable in the future usage.
According to the other method, when all the users use the same work environment, changes made to the work environment by the users other than products stored in the user file storage 707 are discarded. In the present invention, a widely or publicly known technology may be used for the method for providing a work environment except in that products are registered in the user file storage 707 .
At least two methods are possibly adopted as a method for connecting the user file storage 707 and the work environment. According to one method, the user file storage 707 is mounted as a disk area in which only the user can write on the OS constructing the work environment. According to the other method, the user file storage 707 is not mounted on the OS constructing the work environment and the user is let to actively copy the design file in the user file storage 707 .
FIG. 5 shows a process flow of the present system in the simulation mode 316 . Using FIGS. 5 , 2 and 3 , operations in the simulation mode 316 are described in detail.
When the user terminal 107 selects the simulation mode 316 , a simulation is executed by the dynamic computational resource distribution system 100 , the simulation computational resources 101 and the simulation result visualization system 102 .
The dynamic computational resource distribution system 100 is composed of a simulation task input device 704 , a simulation task creating device 705 and a simulation task issuing device 723 . Note that although these devices are independent computers in FIG. 3 , a program for realizing functions of these devices may be executed in one computer.
The simulation result visualization system 102 is configured to include the simulation result visualization unit 715 allocated by the simulation task creating device 705 , and the simulation result visualization unit 715 is connected to a screen data transmitting device 701 of the screen data transmission system 104 .
In Step 307 of FIG. 2 , the user terminal 107 creates a simulation configuration desired by the user using the simulation task input device 704 .
When construction of a simulation object using the simulation task input device 704 is finished, a control of FIG. 5 is started. In Step 501 , the simulation task creating device 705 of the dynamic computational resource distribution system 100 estimates computational resources necessary to execute the simulation configuration received from the user terminal 107 .
Thereafter, in Step 308 , the dynamic computational resource distribution system 100 presents necessary time and cost calculated by the simulation task creating device 705 and the simulation configuration allocated to the computational resources (cluster node 1400 of FIGS. 13 , 14 ) to the user terminal 107 .
The user using the user terminal 107 returns to Step 307 , adjusts parameters in the simulation task input device 704 and requests an estimate to the simulation task creating device 705 again if information presented from the dynamic computational resource distribution system 100 falls short of his desire.
On the other hand, if the time and cost necessary to execute the simulation and presented to the user terminal 107 by the simulation task creating device 705 meet the user's desire, the user instructs the simulation task issuing device 723 to execute the created simulation task from the user terminal 107 in next Step 309 .
When the user terminal 107 instructs the simulation task issuing device 723 to execute the simulation task, the simulation task issuing device 723 secures a necessary number of CPUs and a minimum number of cluster nodes to satisfy a memory amount out of the simulation computational resources 101 in accordance with a command list 1202 generated as the simulation task configuration and illustrated in FIG. 23 in Step 503 .
Licenses of all the software necessary for the simulation configuration input from the user terminal 107 are secured by a license server 724 to be described later and the simulation is started.
In Step 504 , the simulators executed by the cluster nodes 1400 of the simulation computational resources 101 shown in FIGS. 13 , 14 proceed with the simulation while exchanging data with each other.
At that time, the simulation result visualization unit 715 of the simulation result visualization system 102 accumulates data received from one or more simulators (cluster nodes 1400 ) and processes the accumulated data to obtain a graph designated from the user terminal 107 in Step 310 .
If it is designated to present data processed by the simulation result visualization unit 715 in real time to the user terminal 107 , the simulation result visualization unit 715 provides the user terminal 107 with data visualizing the simulation (graph or the like) via the screen data transmission system 104 .
If real-time presentation is not designated, the simulation result visualization unit 715 retains the processed data in the user file storage 707 . In response to a request from the user terminal 107 , the simulation result visualization unit 715 provides the visualized data from the user file storage 707 .
A load on the present system during the execution of the simulation is recorded in the system load/user behavior monitoring system 103 by the following process.
Loads on the CPU and the memory of the cluster node 1400 to which the simulation task configuration is allocated are measured in the simulation computational resources 101 in Step 506 shown in FIG. 5 , and a simulation log is recorded in Step 505 . Data are recorded as a resource usage amount in the resource usage management database 711 of the system load/user behavior monitoring system 103 shown in FIG. 3 .
The system load during the execution of the simulation stored in the resource usage management database 711 is analyzed together with behavior information of the user terminal 107 after the execution of the simulation stored in the operation history database 708 . An analysis result is fed back to a task creation algorithm of the simulation task creating device 705 to improve accuracy in creating the simulation task configuration.
Two methods are possibly adopted as a method for presenting the simulation mode 316 to the user. According to one method, similar to the software creation mode, the task input device 704 and the simulation result visualization unit 715 out of the simulation computational resources 101 are respectively mounted as independent applications and a work environment for simulation execution is allocated.
According to the other method, the task input device 704 and the simulation result visualization unit 715 are presented as applications on a web browser. In the present invention, any widely or publicly known technology may be used for the method for presenting the task input device 704 and the simulation result visualization unit 715 to the user.
The license server 724 of the dynamic computational resource distribution system 100 is a computer holding a license key necessary to start the software introduced to the simulation computational resources 101 .
Normally, the start of commercial software is limited by license authentication to prevent illegal copying. Two methods can be adopted as a method for limiting the start of software by license authentication. According to one method, authentication is performed in each computer using information specific to the computer, for example, an individual identifier of a network interface or that of a hard disk. According to the other method, authentication is performed by one computer and the other computers obtain a license from the authenticated computer.
In this embodiment, the method using the license authentication by the license server 724 is described. However, a widely or publicly known technology may be used for the method for providing authentication in the present invention. Generally, in an environment which includes simulation computational resources composed of a multitude of computers and in which software to be executed is dynamically changed as in this embodiment, the former authentication for each computer increases cost to administrate the computers since the number of necessary licenses increases.
FIG. 7 shows an example of a typical configuration of the simulation task input device 704 of the dynamic computational resource distribution system 100 . The simulation task input device 704 is mounted as a computer for executing a GUI application with a task configuration display region 801 and a tool palette 802 .
The tool palette 802 includes all simulation models usable for simulation configuration as a plurality of part blocks 804 and each part block 804 is composed of one simulation model or a collection of simulation models. Assuming that a multitude of simulation models are registered in the tool palette 802 , the simulation models may be so mounted as to be displayed in a divided manner according to the type thereof in menu 806 .
In an embodiment of FIG. 7 , classification by fields of application such as automobile, aviation, OA and hydraulic machine, classification by physical layers of simulation objects such as electronic and environmental model or classification by simulators for executing simulation models to be described later are presented. In FIG. 7 , the field of automobile is selected from the menu 806 , and simulation models of mechanical parts in an embedded system of an automotive vehicle such as an engine and a motor, driving parts such as an injector and a sensor and electronic parts such as a controller are displayed.
The user can arrange the part blocks 804 selected from the tool palette 802 on the task configuration display region 801 and describe an inter-part connection relationship among part blocks 820 to 825 arranged on the task configuration display region 801 using arrow lines 815 . At this time, the user need not expressly designate by which software each of the part blocks 820 to 825 is executed and to how many I/O interfaces they are connected. Further, the user can cause a parameter setting display region 805 to be displayed for each of the part blocks 820 to 825 arranged on the task configuration display region 801 using the user terminal 107 .
The parameter setting display region 805 displays standard operation parameters of the parts 820 to 825 at first, and the user can appropriately change the operation parameters in conformity with the simulation configuration using the user terminal 107 . Examples of the operation parameters of the models include a step cycle 817 for updating an event, an abstraction level 807 , internal data 808 desired to be visualized by the user, and the like.
The simulation result visualization unit 715 for visualizing data is allocated to the simulation environment by being inserted into the part, the internal state of which is desired to be monitored, or connection between the parts on the task configuration display region 801 . Further, which presentation method is used at that time can be abstractly selected.
In this embodiment, the user designates allocation of a continuous type graph visualization unit 811 for visualization of the engine block 825 and allocation of a discrete type graph visualization unit 821 for visualization of the internal state of the engine control ECU 820 as shown in FIG. 7 .
On a setting display region 814 for parameters relating to the overall simulation configuration, the user sets parameters used by the simulation task creating device 705 at the time of creating a simulation task to be described later.
In this embodiment, the user designates a target end time 816 of the simulation configuration designated from the user terminal 107 . Two methods, i.e. a method for designating a time at which the simulation is desired to be finished as in FIG. 7 and a method for designating the elapse of time can be supposed as a method for setting the target end time 813 . In the present invention, a widely or publicly known technology may be used for this designation method. As just described, the task configuration display region 801 is a GUI for setting and displaying according to an input from the user terminal 107 .
In FIG. 7 , the simulation configuration input from the user terminal 107 by the user can be saved. Specifically, the user can save the simulation configuration on the task configuration display region 801 in a simulation configuration history database 721 by pressing a save button 813 on the task configuration display region 801 . In saving the simulation configuration, the user can set a disclosure range of the saved simulation configuration, the presence or absence of authority for detailed reference/change of the configuration and ON/OFF of edit items of parameters of the individual part blocks using the user terminal 107 .
Hereinafter, the above saved simulation configuration is called a subsystem. FIG. 8 shows a screen presentation example when the subsystem saved in FIG. 7 is reused. By using the subsystem, a created simulation configuration 900 can be reused while being shared by other users.
The simulation configuration 900 saved in the simulation configuration history database 721 by the user is displayed on a user definition menu 906 of the tool palette. If this simulation configuration 900 is arranged on the task configuration display region 801 , the simulation environment constructed in FIG. 7 is developed as in FIG. 8 and parameters set by the user who created the subsystem are displayed on a parameter setting screen 901 . In this example, the parameters include a visualization object 905 , an abstraction level 903 of the entire parts, and a simulation step cycle 902 of each model.
If the user who created the subsystem granted authority for change/reference using the user terminal 107 in advance, a user of the subsystem can refer to/change the detailed parameters of the individual parts constituting the subsystem or add a new simulation model or visualization object in the subsystem.
FIG. 9 shows a configuration example when it is necessary to expressly designate software used in the individual parts as simulation objects in the simulation task input device 704 of the dynamic computational resource distribution system 100 . FIG. 9 differs from FIG. 7 in that tools of all the parts displayed on a tool palette 1000 are designated. A method for arrangement on the task configuration display region 801 and a method for setting operation parameters are common to the above case of FIG. 7 .
According to the present invention, the configuration of the simulation task input device 704 may include all or some of the configuration example of FIG. 7 , that of FIG. 8 and that of FIG. 9 without being limited to any one of them.
FIG. 10 shows a screen image showing an example of a user interface of a simulation task. This user interface presents an allocation result of the simulation task configuration to the simulation computational resources 101 to the user terminal 107 . In this embodiment, the screen display of the simulation task input device 704 is reused and a planned end time of the simulation, total cost for the simulation and its breakdown are displayed on this screen.
Two methods, i.e. a method for designating a time at which the simulation is desired to be finished as in FIG. 10 and a method for designating the elapse of time are supposed as a method for presenting the planed end time of the simulation. In the present invention, a widely or publicly known technology may be used for this designation method. Further, a method for presenting a computational resource allocation result is not limited to the method shown in FIG. 10 .
The task creation operation described in from FIG. 7 to FIG. 10 is defined to be an operation of receiving a created simulation configuration as an input from the user terminal 107 using the simulation task input device 704 of the dynamic computational resource distribution system 100 and converting it into an executable sequence of a simulation task configuration.
In creating the simulation task configuration, parameters of the simulation or computer configuration are adjusted in conformity with the granularity of a simulation model and characteristics of a simulator for executing the simulation model.
The granularity of the simulation model is the size of a minimum unit in the simulation model. A abstraction level largely differs depending on the simulation model, for example, between modeling with a low abstraction level such as a signal line level in SystemC and modeling with a high abstraction level such as a data communication level. This largely changes computation amount necessary for execution of a simulation and communication traffic between parts in a directly coupling relationship.
Generally, the lower abstraction level a simulation model has, the more computation amount and communication traffic are necessary, but it is possible to obtain detailed internal information. On the other hand, the higher abstraction level a simulation model has, the less computation amount and communication traffic are necessary, but time accuracy is low and only a limited internal state can be obtained.
In the case of connecting two or more simulation models having different granularities, it is necessary to synchronize data between the simulation models at regular time intervals. If connection is made without optimization here, the simulation is executed with the granularity of the coarse model and the overall simulation speed is reduced.
Thus, a technique for improving the overall simulation speed by optimizing a synchronization cycle of data in conformity with a site where the simulation is desired to be visualized is important. However, optimization of the synchronization cycle cannot be conclusively estimated before execution of the simulation. Therefore, in the present system, a technique for optimizing a simulation configuration is adopted which treats the configuration of a simulation executed in the past and system loads at the time of executing this simulation configuration as learning data.
FIG. 11 shows an example in which a simulation task configuration 1101 is created by setting a simulation of the engine control ECU as a simulation task in the case of developing a control system for an internal combustion engine as an embedded system. Software for executing each simulation (execution tool in FIG. 11 ), a model for executing the simulation (used model in FIG. 11 ), parameters to be used (used parameters) and identifiers of the cluster nodes 1400 for executing the simulations (execution node in FIG. 11 ) are allocated to the engine control ECU, the air flow meter, the injector and the engine as simulation elements.
FIG. 12 shows a flow chart of task creation by the simulation task creating device 705 of the dynamic computational resource distribution system 100 . This corresponds to Step 501 of creating the simulation task and Step 502 of recording the task configuration in FIG. 5 . A task creation process of the simulation task creating device 705 is described below.
In Step 1203 , the simulation task creating device 705 creates a task using a simulation configuration created using the simulation task input device 704 as an input.
In Step 1204 , the simulation task creating device 705 relates the parts included in the simulation configuration to the simulators to be executed respectively. In relating the parts and the simulators, the types of the simulators (simulation software) necessary to execute the respective parts included in the simulation configuration and information on the granularities of simulation models are obtained by a search (Step 1210 ) in the tool/model database 709 in which information on the simulation models used in the simulation configuration is recorded.
In obtaining, the simulation task creating device 705 refers to the simulation configuration history database 721 in which the simulation task configurations executed in the past are recorded (Step 1212 ). In finding out a history of execution of an equivalent configuration, it is possible to reuse the history data of the simulation configuration history database 721 without referring to the tool/model database 709 .
Subsequently, in Step 1205 , the simulation task creating device 705 allocates tasks of the simulators and the simulation models to the simulation computational resources 101 . At this time, a computational resource management database 706 is referred to (Step 1211 ). Specifically, the tasks of the simulators and the simulation models are allocated to the simulation computational resources 101 to simulate the individual parts of the simulation configuration based on requested computation amounts and communication traffics of the individual parts, and information on computation capability and communication capacity of the simulation computational resources 101 and usage statuses of computational resources recorded in the computational resource management database 706 to be described later.
In task allocation, whether to arrange the cluster nodes 1400 at close positions or at distant positions is determined according to the volume of the communication traffic between the parts. Further, the tasks with huge communication traffic are allocated to the same node. Further, since execution times and data are synchronized between the parts by TCP/IP communication, port numbers used in data communication are also allocated.
Further, the simulation task creating device 705 also couples the simulation result visualization unit 715 and a user interface for presenting the simulation mode in the case of including the simulation result visualization unit 715 that needs to keep displaying a result during the execution of the simulation.
When allocation of the simulation tasks to the simulation computational resources 101 is completed, the simulation task creating device 705 adjusts parameters of the individual simulation tasks in next Step 1206 .
Adjusting the parameters of the simulation tasks includes referring to the simulation configuration history database 721 to searching for histories of parameters of the simulators when a simulation having similar parts, coupling relationship of the parts and cluster arrangement was executed for combinations of the simulators and the simulation models (Step 1212 ).
If a result corresponding to the above search conditions is found, parameters of this simulation are used. If no search result is found, similar configuration histories in the parameters input in the simulation task input device 704 and the simulation configuration history database 721 are searched for and simulator parameters obtained from a configuration with a highly effective simulation result are generated.
The effectiveness of the simulation result is a numerical value evaluating whether or not the simulation result indicates an analysis result and an execution speed meeting the user's desire by analyzing the user's behavior after the execution of the simulation. A flow of simulation result effectiveness analysis is described later.
In Step 1207 , the simulation task creating device 705 confirms a command list 1202 of the simulation tasks to be executed in the simulation computational resources 101 as illustrated in FIG. 23 by confirming the execution parameters corresponding to each combination of a simulator and a simulation model.
By the above process, the types and numbers of the simulators and simulation visualization units 715 , the amount of computational resource, and a coupling relationship of the computational resources necessary for the simulation can be known. Based on these, it can be predicted the amount of time and computational resources required by a similar simulation by referring to the simulation configuration history database 721 .
When anticipated values of the time and used resource are calculated, the simulation task creating device 705 calculates anticipated cost of the simulation to be presented to the user from the user terminal 107 . The above anticipated values are presented to the user. The present system waits until receiving an instruction to execute the simulation or recreate simulation tasks from the user terminal 107 .
If it is instructed to recreate the simulation tasks from the user terminal 107 , the simulation task creating device 705 reduces task creation accuracy of the simulation configuration presented to the user terminal 107 and creates simulation tasks again using different generation parameters (simulation elements).
The task creation accuracy is a numerical value given to each simulation task created by the simulation task creating device 705 and calculated by subtracting 1 or adding 1 based on effectiveness evaluation of the user on the executed simulation tasks.
On the other hand, if an execution instruction is given from the user terminal 107 , the simulation task creating device 705 transfers the command list 1202 to the task issuing device 723 to start the simulation. A widely or publicly known technology may be used for an estimation algorithm of a degree of similarity between the simulation configuration and the history data in the simulation task creating device 705 except in including the operation flow described with reference to FIG. 12 .
In Step 1208 , a computing resource load measuring device 712 observes system loads in the simulation computational resources 101 during the execution of the simulation and records its observation result. Specifically, the system loads (e.g. processor utilization rates) of the respective cluster nodes 1400 of the simulation computational resources 101 are obtained and recorded in the resource usage management database.
In Step 1209 , the simulation task creating device 705 analyzes the simulation result and the configuration of the executed simulation after execution of the simulation and evaluates the effectiveness of this simulation.
After execution of the simulation, the user confirms the visualized simulation result in the user terminal 107 . Which action the user will take according to this result can be obtained by the user behavior statistics device 713 .
If it is revealed from the measurement result of the user behavior statistics device 713 that the user receives the simulation result in the user terminal 107 and repeatedly executes the simulation having the same part configuration again while changing the parameters relating to the operations of the simulators, the simulation task creating device 705 determines that the user is not satisfied with automatic allocation capability by the simulation task creating device 705 and reduces the task creation accuracy of the simulation configuration history.
If it is revealed from the measurement result of the user behavior statistics device 713 that the user receives the simulation result in the user terminal 107 and uses the exact same part configuration and simulation operation parameters, the simulation task creating device 705 increases the task creation accuracy of the corresponding simulation configuration history. The simulation task creating device 705 uses the effectiveness of each configuration history entry of the simulation configuration history database 721 so that a highly effective simulation configuration history is used in the future.
By the above mechanism, the simulation task creating device 705 can improve its own task creation accuracy.
Hereinafter, table configuration examples of the databases used in the task creating device 705 and the like are described. The tool/model database 709 is a database for storing information on arbitrary simulation models usable in the present system. A table configuration 1200 of FIG. 19 shows an example of a table configuration of the tool/model database 709 .
In this embodiment, the tool/model database 709 stores identifiers (part name in FIG. 19 ) of the simulation models, identifiers (tool in FIG. 19 ) of the simulators capable of executing the simulation models, version information (version in FIG. 19 ) of the executable simulators, granularities of the simulation models (model granularity in FIG. 19 ) and the numbers of input/output ports of the simulation models as connection information in FIG. 19 . This table configuration is a minimum table configuration in realizing the present invention and information to be stored may be further increased.
The computational resource management database 706 is a database for managing the state of the simulation computational resources 101 of the present system. FIG. 24 shows an example of a table configuration of the computational resource management database 706 .
In this embodiment, the computational resource management database 706 is a database for storing computing capabilities, node position information, used states, planed return times from the used states and the like of the cluster nodes 1400 constituting the simulation computational resources 101 .
In FIG. 24 , classes 2401 of the cluster nodes are obtained by classifying the simulation computational resources 101 according to its CPU performance and RAM capacity. The classes of the cluster nodes are used for cost calculation in execution of the simulation to be described later.
In this embodiment, position information of target cluster nodes on the network are stored under node arrangement 2402 . In this embodiment, IP addresses are used as position information on the network. The positional relationship on the network can be grasped from the IP addresses and communication traffic can be estimated based on the positional relationship on the network. Generally, the nodes having closer IP addresses can support high communication traffic.
This table configuration is a minimum table configuration in realizing the present invention and information to be stored may be further increased.
The simulation configuration history database 711 of the dynamic computational resource distribution system 100 is a database for storing the configuration of a simulation task created by the simulation task creating device 705 , i.e. the types of simulators used in a certain simulation, simulation models, a coupling relationship among the simulators (simulation configuration), parameters used in the simulators and effectiveness of an execution result of the simulation configuration.
FIG. 26A shows an example of a simulation configuration table 2600 of the simulation configuration history database 711 . In this embodiment, identifiers of simulations (simulation ID in FIG. 26A ), start times (start time in FIG. 26A ), target end times and actual end times (actual end time in FIG. 26A ) of the simulations, a link to another table storing the simulation configuration (simulation configuration file path in FIG. 26A ) and simulation effectiveness are stored.
FIG. 26B shows an example of a simulation configuration table 2601 of the simulation configuration history database 711 . In this embodiment, identifiers of simulators configuration (simulation ID in FIG. 26B ), simulator types, file storage destinations of simulation models, and identifiers of simulation models which directly exchange data at the time of executing the simulation (neighboring configuration ID in FIG. 26B ) are stored. As long as the information shown in FIGS. 26A , 26 B is included, a widely or publicly known technology may be used for other parts of the configuration of this database.
The computing resource load measuring device 712 can be realized, for example, by a system status obtaining program as a standard program of the OS introduced by a system provider and installed in the simulation computational resources 101 . A widely or publicly known technology may be used for the detail of the computing resource load measuring device 712 except that the execution times of the processes, the CPU loads and the RAM usage amounts can be recorded. As shown in FIG. 3 , a program for obtaining the load information of each of the cluster nodes 1400 may be executed by the computer of the system load/user behavior monitoring system 103 .
A configuration example of the simulation computational resources 101 is described using FIGS. 13 , 14 . FIG. 14 shows an example of a minimum structure of a cluster as a constituent element of the simulation computational resources 101 . FIG. 13 shows a configuration example of the cluster nodes as constituent elements of the cluster. The simulation computational resources 101 have a cluster minimum structure 1403 in which one or more cluster nodes 1400 and one or more storage systems 1402 are connected to each other via a communication network 1401 .
Further, the simulation computational resources 101 can have a structure in which one cluster minimum structure 1403 or a plurality of cluster minimum structures 1403 are connected by the communication network 1401 . Any one of LAN (Local Area Network), Internet, WAN (Wide Area Network), dedicated line, wireless network, public network, mobile telephone network can be employed as the communication network 1401 , and the type of the network and a connection structure do not matter. A virtual dedicated network technology such as VPN (Virtual Private Network) may be sometimes applied to the communication network 1401 .
A configuration example of the cluster node 1400 is described using FIG. 13 . A basic configuration of the cluster node 1400 includes elements such as one or more processors 1300 , one or more memories 1303 , a controller 1301 , one or more accelerators 1302 , and a network interface 1304 . The number of each element and connection relationship of the elements are not limited.
Using FIGS. 6 and 3 , an example of a process in the development progress/tool usage status/system usage fee confirmation mode 317 is described.
Information provided in the development progress/tool usage status/system usage fee confirmation mode 317 is regularly analyzed using latest data given by a search 600 of system information at that time by a method to be described later. Specifically, a development progress selecting device 718 in the system load/user behavior monitoring system 103 analyzes the above information using the latest data in creation 603 of a development progress report and creation 604 of a software usage status report. A system usage fee generating device 716 analyzes the above information using the latest data in creation 601 of a system usage fee report and creation 602 of a license fee report.
The development progress report is recorded in a development progress information database 720 , the software usage status report is recorded in a tool usage status database 719 , and the system usage fee report and the license fee report are recorded in a billing management database 717 .
The user who selected the development progress/tool usage status/system usage fee confirmation mode 317 in Step 302 selects the type of the information desired to be confirmed from the development progress report, the tool usage status report and a system usage confirmation report in Step 313 .
When the information to be used is selected in the user terminal 107 , the present system searches the development progress information database 720 , the tool usage status database 719 and the billing management database 717 for the corresponding latest report. If the corresponding report data is found, it is presented to the user terminal 107 via the screen data transmitting device 701 in Step 314 .
The user can limit information browsable by the user in advance in concluding a usage contract of the present system. For example, the user who develops using the present system can receive the development progress report and the usage fee information, but cannot browse the license fee information.
A procedure of analyzing information in the system usage fee generating device 716 and the development progress selecting device 718 in the system load/user behavior monitoring system 103 and configuration examples of databases necessary at that time are described below.
FIG. 15A shows a procedure of calculating a usage fee of the present system to be charged to the user using the user terminal 107 and a license fee to be paid to the software provider from the information in the operation history database 708 , the resource usage management database 711 and a resource price database 710 .
First, a process of calculating the system usage fee to be charged to the user is described. In Steps 1500 and 1501 , the system usage fee generating device 716 searches, for each user, the resource usage management database 711 and the operation history database 708 respectively for a load history of the simulation computational resources 101 and a GUI operation history within a usage time by the user of the work computer system 106 .
In Step 1503 , the system usage fee generating device 716 selects CPU usage, RAM usage and required time of each used function based on a combination of the load history of the simulation computational resources 101 and the GUI operation history of the work computer system 106 .
On the other hand, in Step 1502 , the system usage fee generating device 716 searches the resource price database 710 for a computational resource unit price and a tool unit price for each tool used from the user terminal 107 , using a used computation node as a keyword.
The system usage fee generating device 716 calculates the data collected in above Steps 1502 , 1503 in accordance with the following equation in Step 1504 :
(CPU usage×RAM usage×computational resource unit price+tool unit price)×usage time.
This equation is equivalent to a calculation of multiplying the usage of the computational resources by the usage unit price of the computational resources. The system usage fee generating device 716 calculates and tabulates the system usage fee corresponding to the usage of the functions of the present system for each user of the user terminal 107 .
Subsequently, in Step 1513 , the system usage fee generating device 716 searches the resource usage management database 711 for the storage usage of the user of the user terminal 107 and searches the resource price database 710 for the storage unit price. Further, in Step 1505 , the storage usage and the storage unit price are multiplied and the multiplication result is added to the system usage fee as the storage usage fee. The resource price database 710 is described later.
By Step 1505 , the system usage amount for the user is given by:
∑
UsedTool
TaskRequiredTime
×
(
ComputationalResourceUnitPrice
×
CPUUsage
×
RAMUsage
+
ToolFunctionUnitPrice
)
+
StorageUsage
×
StorageUnitPrice
[
Equation
1
]
In Step 1506 , the system usage fee generating device 716 compiles the total and particulars of the system usage fee added with the storage usage fee calculated above and creates a system usage fee report 2700 as illustrated in FIG. 27 . Finally, in Step 1512 , the created system usage fee report 2700 is registered in the billing management database 717 .
Next, a process of calculating the software license fee to be paid to the software provider is described using FIG. 15B . In Steps 1507 and 1501 , the system usage fee generating device 716 searches the resource usage management database 711 and the operation history database 708 respectively for a load history of the simulation computational resources 101 of each software and a GUI operation history within a usage time by the user of the work computer system 106 .
Subsequently, in Step 1509 , a minute required time of each used function is selected based on a combination of the load history of the simulation computational resources 101 and the GUI operation history of the work computer system 106 .
On the other hand, in Step 1508 , the system usage fee generating device 716 searches the resource price database 710 for a software usage unit price using the function of the software as a keyword and multiplies it by the required time selected above. By Step 1510 , the software license fee to be paid to the software provider is calculated by:
∑
UsedTool
TaskRequiredTime
×
ToolFunctionUnitPrice
[
Equation
2
]
In Step 1511 , the system usage fee generating device 716 compiles the total and particulars of the calculated software license fee and creates a license fee report 2800 as illustrated in FIG. 28 . Finally, in Step 1512 , the created license fee report 2800 is registered in the billing management database 717 .
By the above, the system usage fee generating device 716 creates the system usage fee report 2700 and the license fee report 2800 .
Next, the detail of the resource price database 710 described with reference to FIGS. 15A and 15B is described with reference to FIG. 20 . The resource price database 710 in the system load/user behavior monitoring system 103 stores contract information on the license fee and the system usage fee concluded with the software provider and the user in advance.
A table configuration example of the resource price database 710 is described using FIG. 20 . A storage price table 1730 of the resource price database 710 stores capability, capacity and unit price per unit usage time for each class of storage in the present system.
A cluster node price table 1740 of the resource price database 710 stores the installed CPU, the hardware type, the amount of the installed memory and the unit price per time/unit CPU usage/unit RAM usage for each type of the node.
A tool price table 1750 of the resource price database 710 stores vender information and unit price per function/unit time for each software and each function. Unit price information includes two unit prices, i.e. a unit price to be paid to the software provider and a unit price to be charged to the user.
The resource usage management database 711 in the system load/user behavior monitoring system 103 is a database for recording usage loads on the simulation computational resources 101 , the work environment computational resources 722 and the user file storage 707 .
FIG. 17 shows a table configuration example of the resource usage management database 711 . The resource usage management database 711 is configured to include a storage usage history table 1700 storing a usage history of the user file storage 707 used by the user terminal 107 , a system load history table 1710 storing load histories of the cluster nodes 1400 used in the simulation computational resources 101 and a remote OS usage time table 1720 .
The storage usage history table 1700 records information including the usage for each storage area secured on the user file storage 707 by the user of the user terminal 107 . In this embodiment, user identifiers, used storage amounts and storage class identifiers are recorded.
The storage usage of each user in the user file storage 707 in the work computer system 106 is sequentially monitored by a storage usage tabulation program executed by the system load/user behavior monitoring system 103 .
The system load history table 1710 stores system loads of tasks executed on the simulation computational resources 101 by the user of the user terminal 107 . In this embodiment, the used software, task start times, task end times, the types of the used cluster nodes, average values and peak values of the CPU usage and the memory usage are recorded.
The remote OS usage time table 1720 records the usage time of the user in the work environment computational resources 722 in the work computer system 106 . In this embodiment, the user identifier, the login time to and the logout time from the work environment computational resources 722 are recorded. The operation history database 708 is a database for holding an operation performed on the GUI or file on the present system by the user via the user terminal 107 and a behavior analyzed from the operation history.
FIG. 18 shows a table configuration example of the operation history database 708 . The operation history database 708 is composed of a user behavior raw data table 1820 storing a usage history of the present system by the user from the user terminal 107 , an event table 1810 storing an analysis result of the user behavior statistics device 713 , and a file history table 1800 storing a history of accessing the user file storage 707 from the user terminal 107 for each user.
The user behavior raw database 1820 holds data obtained by the user behavior statistics device 713 from operations of the user on the simulation task input device 704 and the work computational resources 722 as they are. Thus, only an event history of GUI parts of the individual tools such as operations on a mouse, entered texts and the like are recorded in this table 1820 .
The event table 1810 stores data obtained by template analysis of data of the user behavior raw data table 1820 and the file history table 1800 by the user behavior statistics device 713 .
The user behavior statistics device 713 includes stored computer operations corresponding to a GUI operation sequence (template) as a pair, checks the GUI operation history of the user and the template against each other, and outputs a computer operation event determined to have a highest corresponding probability by a statistical means. In the present application, this checking is called template analysis.
By the template analysis of the user behavior statistics device 713 , an operation event for each tool, e.g. which part was handled or which option was selected on the tool can be estimated from the GUI operation history sequence of the user behavior raw data table 1820 . In this embodiment, the event table stores the user identifier, the type of the software, the occurrence time of an event and the content of the event.
In this embodiment, a widely or publicly known technology may be used for the user behavior statistics device 713 concerning the algorithm of the template analysis except for the functions described above.
In selecting a development progress status and a tool usage status, the present system regularly analyzes information without receiving a request from the user and stores latest report files in the databases each time. According to an information analysis method of the present system, a process of producing a simulation result as a development result from a software part as a material is estimated from the usage of the tools and accesses to files.
An example of a process of the development progress selecting device 718 to select a development progress status by referring to a behavior history (operation history database 708 ) of the user is described using FIG. 16A . In Step 1607 , the development progress selecting device 718 searches for a job of each user. This search is on the premise that a job given to a user or a user group using the user terminal 107 , e.g. a simulation including a certain part and software is registered in the system by a manager of the user or the user group or the user himself. A widely or publicly known technology may be used for methods for inputting and storing this job.
Subsequently, in Step 1608 , the development progress selecting device 718 searches the simulation configuration history database 721 of the dynamic computational resource distribution system 100 and the resource usage management database 711 and searches for a history of a simulation task configuration corresponding to the job searched for in Step 1607 . If a search result is found, a dependency relationship of the information relating to this simulation is analyzed in next Step 1609 .
The development progress selecting device 718 executes a search using the identification number of the user or the user group and the corresponding simulation as keywords in Step 1600 . In the resource usage management database 711 , the execution time of the simulation and the information on the software and the file used in the simulation are searched for. In the operation history database 708 , history information of information files on the GUI operations, usage events of the functions of the software and times at which the events occurred are searched for.
In Step 1600 , the development progress selecting device 718 tabulates search results and generates an information flow graph 2100 as shown in FIG. 21 .
The information flow graph 2100 of FIG. 21 has a graph structure that a simulation task given to the user by analyzing a temporal sequence and the flow of operations is a base point, simulation trials and file changes are points and a dependency relationship of the information is an edge. If there is a Step in which the corresponding information is referred to at a later time for information or a file changed in a certain Step such as Steps 2101 and 2102 of FIG. 21 , a dependency relationship is thought to exist between two Steps.
If a plurality of sequences having the same dependency relationship appear through time, the development progress selecting device 718 collectively visualizes these sequences having the dependency relationship as a loop 2103 .
In Step 1602 , the development progress selecting device 718 can select a list of files or software created or changed in the process of executing the simulation job given to the user by the information flow graph 2100 obtained in above Step 1600 and analyzing the development information. In Step 1603 , the development progress selecting device 718 issues a development progress report including an selection result and records it in the development progress information database 720 .
The development progress selecting device 718 also analyzes a loop structure of the information flow graph 2100 . An example of an analysis of the loop structure is as below. If the simulation trial is continued without changing the simulation configuration or the parameters, a self-loop, i.e. a part where an edge extends from a certain point to itself is present in this simulation part in the information flow graph 2100 . The loop structure is analyzed by selecting a layered structure of the loop, measuring work efficiency of a work flow and selecting an achievement degree of the job given to the user besides selecting such a self-loop.
The development progress selecting device 718 creates a development progress report 1604 (illustrated in FIG. 22 ) including a progress rate of the simulation process selected in Step 1602 , the information of the file created in executing the simulation, the number of executed simulations and effectiveness thereof and stores it in the development progress information database 720 . The development progress report 1604 of FIG. 22 is absolutely an example of its configuration and a widely or publicly known technology may be used for a method for adding and expressing information other than those listed above.
Finally, selection of the software usage status by the behavior history of the user executed by the development progress selecting device 718 is described using FIG. 16B .
Since Steps 1607 to 1600 of FIG. 16B are the same as Steps 1607 to 1600 of the development progress status selection flow by the behavior history of the user shown in FIG. 16A , these Steps are not repetitively described. In Steps 1608 , 1609 of FIG. 16B , searches in the resource usage management database 711 and the simulation configuration history database 721 , and the information flow analysis and the generation of the information flow graph 2100 are common to the analysis of the development progress described with reference to FIG. 16A . However, a search is executed using the ID of the software installed into the present system as a keyword in the selection of the software usage status shown in FIG. 16B .
The development progress selecting device 718 obtains the functions of the software and a usage frequency distribution of the parameters from the event table 1810 of the operation history database 708 . Further, the files used in association with the software or information on another software are collected based on the information flow graph 2100 used in the development progress status selection described above.
In Step 1605 , the development progress selecting device 718 processes the collected information into a form that can be visualized as a tool usage status report 2500 as shown in FIG. 25 . The tool usage status report 2500 is stored in the tool usage status database 719 and issued to the software provider (Step 1606 ).
The tool usage status report 2500 of FIG. 25 is absolutely an example of its configuration and a widely or publicly known technology may be used for a method for adding and expressing information other than those listed above.
As described above, in this embodiment, the dynamic computational resource distribution system calculates an arrangement relationship of simulators on the simulation computational resources so as to execute a simulation configuration optimally based on a coupling relationship of parts (mechanism to be developed, hardware, software) in a simulation task input from the user terminal, and constructs an actual simulation task. In this way, a simulation can be executed at a high speed.
Further, for each user of the embedded system development, a simulation or software usage history is selected and recorded with high accuracy, and a development process of each user is selected from the recorded information. In this way, the progress of each user can be easily managed.
Further, by unifying the work computational resources 722 and the simulation computational resources 101 , initial investment for maintenance of a development environment and maintenance cost can be reduced. Furthermore, by unifying the work computational resources 722 and the simulation computational resources 101 , design files (simulation models, parameters, etc.) can be shared and efficiency in embedded system development can be improved even in the case of simultaneous development at a plurality of sites. Particularly, since the simulators or the software are all managed on the unified computer system, embedded system developers need not purchase the software in advance or maintain the software by themselves.
Further, since the cooperation of a plurality of simulators and adjustment of simulator parameters are automated by reusing the past parameters and simulation configurations based on the information collected for each user, quick and accurate simulations can be easily executed even if developers (users) do not have detailed know-how. In this way, efficiency in embedded system development can be improved.
Further, since the developed software and simulation results using this software are safely transferred in the unified computer system, design files can be more easily shared and a risk of leaking information to outsiders can be suppressed.
Second Embodiment
FIG. 29 is a block diagram schematically showing an example of a second embodiment of the present invention. The second embodiment includes a high-security file transmission system 105 in addition to the configuration of the first embodiment. A user terminal 107 or a provider terminal 108 can receive a system usage report, a license fee report, a development progress report and a software usage status report provided from a system load/user behavior monitoring system 103 via the high-security file transmission system 105 .
This eliminates the need to directly connect the user terminal 107 and the provider terminal 108 to the system load/user behavior monitoring system 103 of the present system in obtaining and confirming the reports. This eliminates the need to connect the user terminal 107 and the like to a dynamic computational resource distribution system 100 , a simulation computational resources 101 , a simulation result visualization system 102 and the system load/user behavior monitoring system 103 other than during a development operation, wherefore security can be further improved.
Note that the function of the development progress selecting device 718 constituting the system load/user behavior monitoring system 103 of the first embodiment shown in FIG. 3 may be incorporated into the system usage fee generating device for calculating a system usage fee and a license usage fee incurred by using the present system.
The system usage fee generating device selects a development progress selecting the user's development process in the present system, calculates a system usage fee to be demanded and a license fee to be paid and creates a development progress report and a software usage status report of each user based on screen operation information and file operation information of each user and loads on the simulation computational resources in the present system.
Further, the work computer system 106 of the first embodiment shown in FIG. 3 functions as work computational resources arranged on the network and including a computer remotely operable from the user terminal 107 . Further, the work computer system 106 functions as a user file storage arranged on the network, storing created design files from the user terminal 107 and including a storage which can be shared by other user terminal(s) 107 .
Furthermore, the work computer system 106 functions as a work environment providing device as a device for providing the work computational resources and the user file storage in combination in response to a request from the user terminal 107 . In this way, the work computer system 106 realizes design file creation in the user terminal 107 and sharing of design files by a plurality of user terminals 107 .
Further, the simulation task input device 704 of the dynamic computational resource distribution system 100 of the first embodiment shown in FIG. 3 includes the tool palette from which simulation models usable from the user terminal 107 are selectable and the model construction display region on which simulation models can be arranged. The tool palette and the model construction display region are GUIs enabling the simulation task input device 704 to configure a simulation according to an input from the user terminal 107 .
The tool palette provides a GUI in which one or more simulation models having specific detailed information deleted are arranged. On the model construction display region, simulation models selected from the tool palette are arranged according to an input from the user terminal 107 , the arranged models are connected by lines, and information specific to the simulation models is displayed and set. According to a screen operation using the tool palette and the model construction display region, the simulation task input device 704 constructs a simulation configuration.
Although the devices in the dynamic computational resource distribution system 100 , the simulation computational resources 101 , the simulation result visualization system 102 , the system load/user behavior monitoring system 103 , the work computer system 106 and the screen data transmission system 104 using secure communication of the first embodiment shown in FIG. 3 are expressed as computers, software executed in the devices may be executed by one computer. In this case, the devices in the systems 101 to 104 may be, for example, termed as a user behavior statistics unit.
The software program operating in the present system can be stored in a computer-readable medium after or without being compressed. Any type of medium such as a semiconductor memory, a magnetic memory or an optical disk may be used.
Although the present invention has been described in detail with reference to the accompanying drawings, the present invention is not limited to such a specific configuration and includes various changes and equivalent configurations within the gist of accompanying claims.
INDUSTRIAL APPLICABILITY
As described above, the present invention can be applied to a computer system for designing by executing a simulation and a program of a development system. | The cost necessary for introducing and maintaining a development environment that includes multiple simulators is suppressed, and a sharing of designing information is promoted, to make parameter adjustment of simulators easy. Provided is a service that unifies development environment on a computer provided with: a working computer system that can guarantee that there is no leaking of designing files; a user behavior monitoring system that collects utilization history of simulators or software, for each of the users, and selects development process of each of the users from the collected information; and a dynamic computational-resource distribution system that can conduct an automatic optimization of a complex simulation configuration, from information collected by the aforementioned user behavior monitoring system. | 99,225 |